Installation (4.0L)

CAUTION: Synchro Positioning Tool (303-638) MUST be used during installation of synchronizer assembly. Failure to follow this procedure could cause fuel system control to be out of time. This could possibly cause engine damage.

It is very important to coat the gear on the camshaft synchronizer with engine oil prior to installation. Failure to do so could result in gear failure upon engine start up.
Install Synchro Positioning Tool (303-638) on camshaft synchronizer by rotating the tool until it engages into notch in camshaft synchronizer housing and the armature. See Fig 1.

Fig 1: Installing Synchro Positioning Tool (303-638) On Camshaft Synchronizer (4.0L)
Courtesy of FORD MOTOR CO.
Install camshaft synchronizer into engine block with Synchro Positioning Tool (303-638) attached. The arrow on the special tool should be pointing to 60 degrees off the engine centerline. See Fig 2.

Fig 2: Installing Camshaft Synchronizer - 1st Step (4.0L)
Courtesy of FORD MOTOR CO.
Rotate Synchro Positioning Tool (303-638) clockwise slightly to engage the oil pump the oil pump intermediate shaft. Continue downward motion, twisting the tool lightly until the synchronizer gear engages the camshaft gear.
With the synchronizer clamp flange seated against the engine block, the arrow on the Synchro Positioning Tool (303-638) points 15 degrees from centerline of engine. See Fig 3.

Fig 3: Installing Camshaft Synchronizer - 2nd Step (4.0L)
Courtesy of FORD MOTOR CO.
Install hold-down. Tighten bolt to specification. See TORQUE SPECIFICATIONS .
Remove Synchro Positioning Tool (303-638) from camshaft synchronizer. Install CMP sensor to synchronizer. See REMOVAL & INSTALLATION (3.0L & 4.0L) . Connect negative battery cable.
On Explorer models, install upper intake manifold. See REMOVAL & INSTALLATION (4.0L VIN X) under UPPER INTAKE MANIFOLD.