Ugh! Any sympathizers replacing cam sync?

[rhekman]

Thanks to everyone here and a big kudos over on the Explorer forums for great pics and instructions on replacing the cam synchronizer on my '95 Ranger 4.0L.

All I can say after the experience is what a PITA. I know I'm not the fastest shade tree mechanic, but 10 hours over several days was not fun. Also, WTH was Ford thinking stuffing this part under the upper intake and next to the firewall? I swear I was laying over the engine compartment for at least 45 minutes working that stupid thing back and forth before it finally let go of it's hold in the block.

Warning to anyone else with a '95 4.0 OHV. Napa and O'Reilly's both had the part number by vehicle application mixed up with the two piece black plastic cap style sensor from 96 and up models. I had to tell them I was running a '94 to get the right part. This post was invaluable to tell the difference: http://www.explorerforum.com/forums/showthread.php?t=233415

The 99$ probe camera I picked up from Harbor Freight was invaluable for verifying the location of the vane against the calibration marks in the sensor window.

Unfortunately after putting everything back together I'm now dealing with a slow to drop idle RPM and codes P0171 and P0174. I suspect based on other postings here and elsewhere that I should have replaced the upper intake manifold gaskets. Apparently I have tearing the intake off AGAIN to look forward to.

Anyone else out there feeling my pain?

 

[Destroyer000]

been there done that man... check the egr tube in the intake .. you might have a big leak right there... my buddy just had to replace his dorman sensor.. since it was chirping.. tookem about 20 min to do.

i just swapped in a sohc into my 95 and low an behold i have a cam sensor code haha

 

[snoranger]

i just swapped in a sohc into my 95 and low an behold i have a cam sensor code haha

Welcome to my world.

I have a plan to do away with that check engine light and replace it with a wait to start light.

 

[97RangerXLT]

oooh a diesel conversion coming on?

What kind of donor are you using? the 3.9 in your info below your avatar?

AJ

 

[snoranger]

oooh a diesel conversion coming on?

What kind of donor are you using? the 3.9 in your info below your avatar?

AJ

I dont want to hijack the thread, so just check out the 4bt swap link in my sig.

 

[rhekman]

Sno, I just caught up from beginning to end on your diesel swap thread. I love it, and can't wait to see it finished.

BTW, my P0174 and P0171 codes are fixed now that I resealed the intake. The main issue was indeed the EGR tube (you can see in the "bad" pic below how off it was, and the rubber seal was very deformed). Overall took me about 45 minutes not counting a break for supper in between.

I picked up replacement upper intake gaskets for insurance even though a carb cleaner test only pointed to the EGR, and since I had to take the upper off regardless. I think Napa's website has the wrong part number for the intake gaskets on a '95. At least the picture online for the '95 application showed a flat one piece gasket, which is not what my truck has. Ordering the 96 intake plenum gasket set seemed to do the trick. At $5.99 I can't complain, and there was an extra set in the box!

EGR tube seal was a different story. I ended up just going to Ace Hardware and grabbing a combination of a flange washer and an o-ring from the plumbing department. Pics follow (sorry the last one is a bit out of focus, but you get the idea).

Just a liiiittle bit off

1 5/16" OD I believe...

A little silicone gasket sealer to be sure.

Extra o-ring for insurance.