I'm not an expert but I do own a '98 with the SOHC V6. My thoughts are:
Call or visit the dealer and tell them that the noise is back. Find out what they will do for you if anything or what they advise.
As I understand it, there are two timing chain tensioners--one front and one rear. Perhaps only the front was replaced originally and now the rear one is failing. Or the front one has gone again. Maybe some other component was damaged by the chain when the original tensioner was defective, and that's the noise that's showing up now.
None of these possibilities sound good. Good luck.
Kens answer is a good one and I can't think of anything to add to his take on the concern.... Yes, there is a rear timing cassette.... yes, it can go bad, too. Yes it could be a repeat of the front failure. Further diagnosis is going to be required. At this point in time, it looks like there will be no help from Ford due to the ae of the vehicle (but it never hurts to ask).
As a DIY proposition, on a scale of one to ten, I rate this as likely about an 11... special tools and considerations need to be taken into account (I realize that you haven't mentioned fixing it yourself, but you did let my foot in the door).
Just to rub the bad part in (sorry, my week has been like that, too)... if it is the rear cassette, the motor has to come out to do this job properly.
FWIW, at this point we are presupposing a concern.... we do need to be sure of our diagnosis to prevent the replacement of good parts.
So this is the part that goes in the back of the engine and requires the whole engine to be pulled out?
Also, looking fro this part number on fordpartsonline.com brings up: "Part Number YL2Z6M289AA was Superseded with 4L2Z6M289AA". Is it possible that to original part was replaced by another prone to be defective part instead of the new, redesigned part?
If I'm not mistaken, and quite sure someone will correct me if I am, that particular 'superseded' part number does not indicate an updated, redesigned, or second version part. If this was a second version part, the extension would have changed to 'AB', 'AC', or so on, instead of remaining the same 'AA'. I believe the first three digits of the part number reflect nothing more then the decade and year of manufacture.
It's a bit embarrassing but I think I found the source of the problem. Seems like I was a bit low on oil. I added 2Q and now the noise seem to be gone. I'll keep on driving to see if I can hear it again.
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