Engine knock getting worse, ideas on next steps

mgroeger

TJ Enthusiast
Original poster
Joined
Aug 24, 2018
Messages
807
Location
Hurricane, UT
'04 LJ, auto, 120k miles

Lately my engine has been sounding more like a diesel then a proper 4.0L. Did some research and it looks like I'm one of the lucky ones that has something going on in terms of a piston skirt breaking off or a rod bearing.
Obviously we won't know until the oil pan gets pulled and a proper diagnosis can be done.
A friend of mine is an A++ mechanic (actually used to work on the electronics of the Apache helicopters and had his own shop) and he is willing to do the work (paid) and has rebuilt about six of these engines in the past.
At the end of the day it comes down to $$$$. He said we can crack it open and the pistons could be fine, the crank shaft not scored and simply find a bad bearing. That would be the best case and he said at that point we'll just replace all the bearings put it together and off you go.
Worse case, crank is scored, cylinder walls are scored, piston skirts cracked, etc...
Personally he said if things are really bad (if it were his) he'd completely overhaul the engine; remove the block, tear it down, have it machined 10% over, new pistons... the works. That way it's' a brand new engine.
Also could get a stroker $$$$$$$ or simply throw a low mileage junk yard engine and pray it doesn't have the same problem.
Obviously I'm praying for option A - the cheapest and quickest. Has anyone been down this road and can offer any advice? I also asked "how much longer do I have"? His response was if this was a book you're at the last chapter or two and the last chapter describes how the engine blew :/
I will keep this thread updated.
Guess my crappy uncomfortable driver's seat is now a distant second place to be dealt with.
 
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Sorry if I've mentioned this before but my chain went out before that mileage and sounded like you are describing. It's easy to check. It does not rattle like a chain, it knocks like a muffled rod as the cam bounces uncontrolled and the cam sits at the same height as the pistons.
 
Here's a link to the video. I think it captures pretty well what's going on. Stethoscope will be here tomorrow to try and pinpoint the sound better. Will be poking all around the engine to see what I can detect and then post here.

 
Just noticed when I was in the front of the engine that the tapping was the most dominant noise. Let me know if anyone wants video of a specific spot.
 
Put a breaker bar on the crank and move it back and forth. It takes two seconds to check the chain. Very unlikely it is your problem but it takes little effort to check and is an easy fix which makes it worth taking the time to check. With an engine that noisy it will be easy to feel play in the chain when you move the crank.
 
I know this sound!

I had it in my '04 TJ. I'm almost certain it is the timing chain. I have around 107,000 miles on my 4.0. I had the oil pan off while doing my rear main seal. I decided to finger the timing chain and it had way too much slack in it. Decided to tear apart the front end and measured the chain deflection and it was around 3/4" - 1" of play! Too loose! Replaced the chain and gear set and all is good.

Here's the list of mopar part #s if needed.

Front Cover Gasket: 53020487
Front Cover Seal: 33004681
Timing Gear Set: 53020443
Timing Chain Guide: 33003446
Timing Gear Set: 53010557AA
Timing Chain: 53020444
 
If that is your noise, I really don’t think that’s a bearing or a skirt. I’m hearing lifter noise in that video, not rod knock.
 
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If that is your noise, I really don’t think that’s a bearing or a skirt. I’m hearing lifter noise in that video, not rod knock.

There is def lifter noise from the front and between the fan and lifter it is hard to hear the knocking but it is def there.
 
Bottom end noises are most prominent right after the throttle is released, valve noise is typically constant and picks up/drops off with engine speed. Lightly tap the throttle and listen for the knock to change tone as the engine speed begins to drop. If it does you're almost guaranteed to have bearing issue.
 
Bottom end noises are most prominent right after the throttle is released, valve noise is typically constant and picks up/drops off with engine speed. Lightly tap the throttle and listen for the knock to change tone as the engine speed begins to drop. If it does you're almost guaranteed to have bearing issue.

You have described exactly what is going on. Lovely, looks like a possible rebuild is in the near future. Next step is to drop the pan and see what I got down there.
 
You have described exactly what is going on. Lovely, looks like a possible rebuild is in the near future. Next step is to drop the pan and see what I got down there.
Not sure how it is with the 4.0, but I know with a Honda engine it doesn't take very long to go from a bottom end knock to a destroyed crank and rods. If it were me I would avoid driving it until you solve the problem.
 
Not sure how it is with the 4.0, but I know with a Honda engine it doesn't take very long to go from a bottom end knock to a destroyed crank and rods. If it were me I would avoid driving it until you solve the problem.

It's heading to my buddies house within the next few days. Going to pull the pan and see where we go from there. If it needs a new crank and complete rebuild I think I will go with a crate motor and pick up a warranty for around the same price or a little more. If anyone has any recommendations in terms of a rebuilt engine I'm all ears.
 
What your oil look like can you get a magnet up the drain hole and see what it looks like or small inspection camera in the oil pan drain plug, I had a I6 wj where the number 6 piston skirt went that sounded a little like that
 
It's heading to my buddies house within the next few days. Going to pull the pan and see where we go from there. If it needs a new crank and complete rebuild I think I will go with a crate motor and pick up a warranty for around the same price or a little more. If anyone has any recommendations in terms of a rebuilt engine I'm all ears.
Hope it hasn't gone that far. 🤞 I don't know any good shops that have rebuilt engines for the Jeep, sorry man. Maybe one of the OG guys can help you out. Let us know what you find when you get the pan off.
 
Mine sounds similar, definitely following this thread. Was hoping to get a couple years out of the 4.0 before having to dig into it but might go straight to an LS. I have a buddy whos done one in a TJ and he said its not super complicated.

Keep us posted on what you find. I've been thinking it was bearing so was going to run it till it let go and go new but if its just a timing belt I'll get on that ASAP.