2014 Roush Raptor startup 'tapping' sound?

Viccern

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All of a sudden (about a month ago), I started noticing a tapping sound when I startup my 2014 Roush Raptor. (144k miles).. from inside it sounded like something was loose in a cupholder or something so I ignored it but after a few trips, I quickly realized it was an engine noise. My problem initially, was by the time I got out to check the noise from outside the cab, it was almost inaudible. With that said, I started doing remote starts and listening and low and behold, it is SUPER loud (not sure if it's always been this loud or if it's gotten worse in the past few weeks) from the outside. The tapping noise quiets down as the engine settles into a lower rpm idle, and that's why initially I didn't hear it when I got out to check.

After researching and reading online, the first thing everyone screams is CAM PHASERS, but I was thinking my tapping noise was going away once it started lowering the rpm to idle so I questioned that. There are many online that state that these 6.2L engines just "make that sound" and they deal with it. I refuse to believe what I'm hearing is normal/not harmful. I let the truck run this past weekend until the noise settled down and I popped the hood and I can still hear the tapping from the running engine, just much quieter. I can't tell if it's coming from the cylinder heads or really even if it's only in one spot, but it seems much louder on the passenger side. I checked the plugs/coil wires and everything seems to be seated properly.

I've read everything from cam phaser problem, to broken valve spring, to stuck lifter letting oil drain out of the cylinder at shut down that takes a few seconds to recharge once you startup next time and even swapping the type of oil filter you use to reduce "backpressure" , but before I take my daily driver out of service for weeks and potentially let a mechanic go with the "standard" expensive cam phaser replacement that might not solve this, I wanted to throw this out to see if anyone else had this specific problem. Here are videos of the sound from startup and then idle:

 

FordTechOne

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In the first video it sounds like an exhaust manifold leak, but in the 2nd video it sounds more like a failed lash adjuster or broken valve spring. Does the truck run rough or misfire? Broken valve spring(s) will typically cause those issues, but it depends where the spring broke. Either way I wouldn’t continue to drive it, if a spring it broken you risk dropping a valve, which will cause serious engine damage.
 
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Viccern

Viccern

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Doesn't run rough in my opinion... it's never been the most balanced/smooth motor, but I've not noticed anything driveability or shudder wise since I started hearing this. If it was a valve spring, curious why the noise would get noticeably quieter at idle after it settles down from startup?
 

Dane

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That sir, is an exhaust leak. Probably a cracked passenger side manifold. I went through two stock exhaust manifolds on mine after I put my Roush on, and that's exactly what it sounded like - or as best as I can judge by video. I now have a full Kooks system.
 

FordTechOne

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Doesn't run rough in my opinion... it's never been the most balanced/smooth motor, but I've not noticed anything driveability or shudder wise since I started hearing this. If it was a valve spring, curious why the noise would get noticeably quieter at idle after it settles down from startup?
If it was a valve spring, it would not go away, but the intensity can change with RPM.

I’d start with checking the passenger exhaust manifold based on the information Dane posted about having issues with cracked manifolds when a supercharger is installed.
 
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Viccern

Viccern

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I'm trying to get it in to see the only Roush Certified mechanic within 6 hours of here... I'll update as soon as I know more. Thanks guys. I'm praying it's exhaust manifold... that would be an easier repair....upgrade. :)
 

ToddReynolds

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That sir, is an exhaust leak. Probably a cracked passenger side manifold. I went through two stock exhaust manifolds on mine after I put my Roush on, and that's exactly what it sounded like - or as best as I can judge by video. I now have a full Kooks system.
Do you have the Kooks long tube headers and green cats??? I have a Borla cat back already installed and have the Kooks Headers and Green cats to install, long term goal is Whipple. If I install headers prior to Whipple will I need a tune??? How do you like the Kooks setup
 

HighHP

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Hard to tell from a video, but that does not sound like internal engine noise. My first thought while listening was exhaust manifold/pipe related.
Let us know what you ultimately find.
 

Dane

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Do you have the Kooks long tube headers and green cats??? I have a Borla cat back already installed and have the Kooks Headers and Green cats to install, long term goal is Whipple. If I install headers prior to Whipple will I need a tune??? How do you like the Kooks setup
I do have the full Kooks dual with green cats setup. I wouldn't buy it again. It immediately started rusting - and I'm in Denver, not the rust belt. I put it on a couple years ago and it looks like garbage now - not that I care about the looks too much, but the mega rusted ass bolts are super fun. Parts have fallen apart, some covered under warranty (resonators fell apart internally), some not (mufflers). Maybe they would have been, but it's impossible to get a hold of Kooks. I had to replace the mufflers entirely cause they just tore apart from general use, not from impacts or anything. The whole assembly has split in half at the rusty clamps probably six times, but I got REALLY good at putting it back together. I had it down to about 5 minutes, carrying the proper tools in the bed. After the last time I went in and had it welded together, no more clamps. I have to constantly tighten the flange connections at the front of the setup when I hear them leaking. In short, Kooks sucks, and you can't talk to them. Sorry you already have their product. I'll never buy their junk again. At least the cats have held up.

I'm not sure about needing a tune prior to the Whipple. I'd recommend asking JDM, but I want to guess it would be beneficial to get one, but I don't know if you NEED one.
 
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