After fighting this issue for 4 weeks, I have discovered the root cause to this particular issue. THIS IS NOT A TUNING RELATED ISSUE, IT'S A MECHANICAL ISSUE!
Here's what I've found.
As I mentioned last week, I have a 2020 Mustang GT A10 with the same exact issue. We tore it down and checked mechanical timing 3 times, both primary and secondary, replaced the Cam Position sensors, VCT actuators and VCT Phasers. The issue still persisted.
Spoke to Comp Cams about the issue. They state it is a tune related issue. Customer is tuned by Lund so I spoke with Brandon at Lund Racing via email through the customers email thread. Brandon basically told me there's a mechanical issue on bank 1 (as we already know) and it's not tuning related.
At this point, I flashed the stock map back on the vehicle, wrote my own map, opened the VCM scanner and took a log.
Logged vehicle with ECT at 64F Degrees. Started vehicle and it's all smooth and quiet. Oil pressure between 89-92PSI. Once the vehicle starts warming up passed 140F degrees and oil pressure starts lowering below 50psi, The faint small ticking will begin to sound, VCT intake is at 20 degrees and VCT exhaust is at 0 Degrees.
As the engine warms up past 160F Degrees and Oil Pressure lowers below 40psi, the ticking will become loud, then the VCT intake will try to go to 30 degrees and that's when the ticking becomes clacking, BUT ONLY ON BANK 1 INTAKE CAMSHAFT! You'll see very erratic VCT readings on Bank 1 Intake Camshaft.
After 30 Seconds of Clacking and the PCM attempting to control the Camshaft, It will trigger a failsafe and reset all cams to 0 Degrees and the noises will go away. Code P0340 (Sometimes Code P0344) will be Illuminated.
Gathering my data and going over the logs, there is an internal oil leak between the front of the camshafts and the VCT Phaser.
Requested the customer to bring me his stock camshafts (L&M Intake Cams Were in there previously and no longer wanted to run them) and began tearing down the front of the engine for the 4th time.
Pulled Bank 1 Intake Camshaft out and compared it to the stock camshaft and here is what I found.
Picture 1 shown here, the stock camshaft has a straight cut on the center where the oil will feed the VCT Phaser into the correct oil channels.
Attachment 104642
Picture 2 shown here is the Comp Camp Stage 2 Mutha' Thumpr, the center of the camshaft has a chamfer machined on the center where the oil feeds and the size of the oil channels seem a bit smaller than the stock camshaft.
Attachment 104644