Quick questions. Doing camshaft synchronizer replacement.

[runfrombears]

My mercury 2002 Sable vulcan must be a little different because my wire harness that sits just above the camshaft sensor is surrounded by hard plastic that does not allow me to bend or move the wires. I actually just completely shattered and broke this shell off in order to get access.

My questions:

1. I removed the cam shaft sensor and now have full access to the synchronizer. Is there another bolt that must be loosened or will the synchronizer just pop out? Should I use some pliers to yank it out?

2. Now that my wires will be exposed to heat since I broke this plastic shell off. What sort of tape can I get as a replacement to protect all these wires from the heat?

Thanks, this would have been an easy job had my car not had those bloody wire protectors above. I had to remove the throttle the air flow, the whole shabang because of this crap. Where I could have just move the wires out of the way and plopped her back in...sigh who designs things like this?

Thanks so much!

[downhill]

The syncro will pull straight up. Soak with a little spray lube around the place where it is in the block. Mark and replace in the same position. You could get a new wire loom at the Junk Yard. Also they make insulation you can wrap around the wires in question.

[Jeff K]

I assume you removed the syncro hold down bolt? Look down where the syncro goes into the engine for the bolt.

[runfrombears]

Originally Posted by Jeff K

I assume you removed the syncro hold down bolt? Look down where the syncro goes into the engine for the bolt.

The only bolt I saw was some sort of hex type.

[runfrombears]

Originally Posted by downhill

The syncro will pull straight up. Soak with a little spray lube around the place where it is in the block. Mark and replace in the same position. You could get a new wire loom at the Junk Yard. Also they make insulation you can wrap around the wires in question.

Thanks, theres no way I'm going to try to install that plastic thing. It's half broken because I couldn't figure out how to remove it, let alone install it. I'll just use a bunch of insulation and tape.

[runfrombears]

So I got the old one out, and the new one in, but I am having trouble! Please bear with me , I am a total novice.

I am trying hard to get it back into the original position but the teeth on the gears only allow for so much precision. Please take a look at these images. One of the original, and 2 options that the teeth let me have. I can not get it to go back to the same place no matter how many times I try, the teeth just won't allow it. Could have something moved?

[behlinla]

Did you turn the engine at all between removal of the old one and insertion of the new one? Are you using the Motorcraft replacement part or a cheaper Dorman or Cardone part?

If you got lost, then you'll have to turn the engine to an index point (such as TDC-C #1) and use an alignment tool or other method. Here's one method: replace Camshaft synchronizer failed

[runfrombears]

Originally Posted by behlinla

Did you turn the engine at all between removal of the old one and insertion of the new one? Are you using the Motorcraft replacement part or a cheaper Dorman or Cardone part?

If you got lost, then you'll have to turn the engine to an index point (such as TDC-C #1) and use an alignment tool or other method. Here's one method: replace Camshaft synchronizer failed

Thanks for the response. Car hasn't moved, yes it is motorcraft part. I assure you I won't be bringing anything to top dead center. I can barely do this simple job, let alone figuring out TDC?

I will try some more tomorrow, already tried 10 times putting it in and out without any success. Keep in mind that you people are my only hope for this as, I do not take a $500 car to a mechanic

Thanks to these forums and youtube I was able to get this far. That is saying something since I am a clumsy buffoon.

[behlinla]

Originally Posted by runfrombears

Car hasn't moved, yes it is motorcraft part.

Just to confirm the engine hadn't been cranked or started either, correct?

If you can't find another tooth in between A and B, then your best bet is try the method used in my link.

[runfrombears]

Originally Posted by behlinla

Just to confirm the engine hadn't been cranked or started either, correct?

If you can't find another tooth in between A and B, then your best bet is try the method used in my link.

That is correct, thank you for taking the time to answer my question. Very much appreciated!