Another camshaft position sensor thread

[gander]

Hi, My truck is a 97 Ranger XLT 3.0L with 5 speed transmission.
A little history first: About 4 years ago I changed out the synchronizer and sensor with one from NAPA. I read the threads of here and just marked everything, pulled the old one, match marked the new one and installed it. I have the 97 Ford factory manuals but went by the articles on here. The truck ran fine until recently and started throwing check engine lights. I checked the wiring, changed out the connector and am still getting check engine lights. I started second guessing myself that maybe I was off a gear tooth on my installation so I decided to go by the manual and replace the one I installed with a Ford synchronizer. New problems are:

1. The synchronizer in the truck is stuck. It will wiggle a little but not come out. Any tricks of the trade to get it moving. Can't really get much of a grip on it and hard to get a pry bar on. Btw, the hold down bolt is off.

2. The manual says to set no. 1 cyl to tdc on compression stroke, remove old sync., install the synchro positioning tool on the new synchronizer, stab it in the hole and rotate to 75 degrees ccw from the engine centerline and install. The trouble is at about 45 degrees the camshaft position sensor hits an engine bolt and won't go the full 75 degrees that the book calls for. Here's the pic from the manual.

Btw, at present the sync(the one I installed 4 years ago) is set at about 25-30 degrees ccw from engine center line. I passed 3 or 4 state inspections and ran well in that position.

Anybody else ever run into this. Any and all comments and help greatly appreciated.

 

[Rearanger]

Btw, at present the sync(the one I installed 4 years ago) is set at about 25-30 degrees ccw from engine center line. I passed 3 or 4 state inspections and ran well in that position.
Anybody else ever run into this.

Yes. Here's a link to my experience:
http://www.therangerstation.com/forums/showthread.php?t=144547&page=2

I found 28* to be the correct position, which would match your 25-30*. My truck runs exactly as it did with the factory setting. I'd make sure the sensor flag is centered in the pickup on TDCC.

Are you trying to pull the old cam syncro with the alignment tool installed?

 

[RonD]

Manually rotate crank 45deg one way then the other way, it will come out.