I'm down to the exhaust manifold, cam&bearings, or wrist pin.
When I was under the engine the pistons did have play, felt as there was a ball joint instead of a wrist pin, sound problematic? Maybe 1/4 in play in a circular motion, when I pulled rod bearings.

 

Didn't have that, but upon replacing bearings there was one bearing half that was snapped in 2 pieces.

 

New crank and new bearings..were installed when this was seen..

 

Yes, why?

 

No crank, main and rod bearings

 

Risky choice there...id get the hose like I suggested make sure its not the manifold it acts like the old funnel people used to hear with...

 

I'll hunt down some hose, how do those pistons sound to you?

 

Im on the other side of the united states to me I hear a normal 4.0 that could possibly have a lifter tick or exhaust leak best I can do from here .

 

Sounds good, thank you.

It still knocks without muffler and cat, can it still be the manifold? Eliminated back pressure

 

seeing that bearing, i would pull the oil pan down and check the new bearings in that same journal. i bet you have an issue their, bearings dont break in half for no reason... can you post pics of the crank journals, those bearings are severely worn out....

 

WTF. Why go any further.

 

Not saying this has anything to do with your noise, but for future reference, you don't want to crank the engine with the starter prior to first start (or at least keep it to a bare minimum). It wipes all the assembly lube off the cam/lifters.

 

See also post #13.

 

This was with the bearings off, and pistons pushed up... They were just rotating in the cylinder...

 

I'll get pictures up tonight.