Ford - Aerostar - Parts Catalogue - 1995 - 1997

Parts List & Operating Instructions Parts List & Operating Instructions for Form No. 107267 No. 6489 Ford Cam and Valve Train Tool Kit 511532 (6009) 511555 (6020) 511533 (6466) 511534 (6467) 511535 (6468) 511536 (6469) 511537 (6470) 511538 (6471) 511539 (6472) 511540 (6473) 511541 (6474) 511542 (6475) 511543 & 511544 (6476) 511545 (6477) 511546 (6478) 511547 (6479) 511548 (6480) 511549 (6481) 511550 (6482) 511551 (6483) 511552 (6484) 511553 & 511554 (6485) 1 Parts List & Operating Instructions 2 Parts List & Operating Instructions Form No. 107267 Ford Tool Application Chart Year Model Engine Tool Description Part No. Ford American Part No. Ford Global Part No. 1995-1997 Aerostar 3.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1996-1998 Aerostar 4.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1994-2002 Contour 2.0L 4 cyl. VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 1997-2002 Contour 2.0L 4 cyl. VIN 3 Crankshaft TDC Timing Pin 6475 (511542) T97P-6000-A 303-574 1999-2002 Cougar 2.0L VIN 3 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 1997 Cougar 3.8L V6 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1991-2008 Crown Victoria 4.6L 2V V8 Cam Positioning Tool 6009 (511532) T91P-6256-A 303-380 1992-2008 Crown Victoria 4.6L 2V V8 Cam Positioning Tool 6020 (511555) T92P-6256-A 303-413 1997-2002 Crown Victoria 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2008 Econoline 4.2L V6 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1997-2009 Econoline 4.6L VIN W Cam Holding Tool 6477 (511545) T96T-6256-B 303-557 1997-2014 Econoline 4.6L VIN W Cam Positioning Tool 6020 (511555) T92P-6256-A 303-413 1997-1998 Econoline 4.6L & 5.4L V8, 6.8L V10 Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2002 Econoline 4.6L & 5.4L Cam Positioning Tool 6476 (511543 & 4) T96T-6256-AR 303-S568 1997-2002 Econoline 5.4L V8 Cam Holding Tool 6477 (511545) T96T-6256-B 303-557 1997-2002 Econoline 6.8L V10 Cam Positioning Tool Cam Holding Tool 6476 (511543 & 4) 6477 (511545) T96T-6256-AR T96T-6256-B 303-S568 303-557 2012-2014 Edge 2.0L VIN 9 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2001-2004 Escape 2.0L VIN B Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2013-2014 Escape 2.0L VIN 9 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2005-2008 Escape 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2009-2014 Escape 2.5L VIN 7 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2005-2008 Escape Hybrid 2.3L VIN H Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2009-2012 Escape Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 1997-2002 Expedition 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2002 Expedition 5.4L Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool Cam Holding Tool 6009 (511532) 6020 (511555) 6476 (511543 & 4) 6477 (511545) T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B 303-380 303-413 303-S568 303-557 2012-2014 Explorer 2.0L VIN 9 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 1996-1998 Explorer 4.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1997-2008 Explorer 4.0L SOHC VIN X Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 3 Parts List & Operating Instructions Ford Tool Application Chart Year Model Engine Tool Description Part No. Ford American Part No. 1997-2011 Explorer 4.0L SOHC V6 VIN E Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) 1999-2002 Explorer 4.0L Push Rod V6 Cam Sensor Synch Tool 6483 (511551) 1997-2002 Explorer 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1996-1998 Explorer 5.0L V8 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1999-2002 Explorer 5.0L V8 Cam Sensor Synch Tool 6470 (511537) 1997-2004 F-150 4.6L VIN 6 Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2010 F-150 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2008 F-Series Truck 4.2L Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1997-1998 F-Series Truck 4.6L Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1997-2002 F-Series Truck 4.6L Cam Positioning Tool 6476 (511543 & 4) T96T-6256-AR 303-S568 1997-2009 F-Series Truck 4.6L VIN W Cam Holding Tool 6477 (511545) T96T-6256-B 303-557 1997-2002 F-Series Truck 5.4L Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6476 (511543 & 4) 6020 (511555) T91P-6256-A T96T-6256-AR T92P-6256-A 303-380 303-S568 303-413 1997-2002 F-Series Truck 5.4L Cam Holding Tool 6477 (511545) T96T-6356-B 303-557 2012-2014 Focus 2.0L VIN 2 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2000-2004 Focus 2.0L VIN 3 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2002-2004 Focus 2.0L VIN 5 Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2005-2011 Focus 2.0L VIN N Crankshaft TDC Timing Pin 6475 (511542) T97P-6000-A 303-574 2005-2012 Focus 2.0L VIN N Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2003-2007 Focus 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2004-2007 Freestar 3.9L VIN 6 Cam Sensor Synch Tool 6470 (511537) 2004-2007 Freestar 4.2L Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 2013-2014 Fusion 2.0L Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2006-2009 Fusion 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2010-2014 Fusion 2.5L VIN A Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2010-2014 Fusion Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 1991-2008 Grand Marquis 4.6L 2V Cam Positioning Tool 6009 (511532) T91P-6256-A 303-380 1992-2008 Grand Marquis 4.6L 2V Cam Positioning Tool 6020 (511555) T92P-6256-A 303-413 1997-2002 Grand Marquis 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 2005-2008 Mariner 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2009-2012 Mariner 2.5L VIN 7 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2005-2008 Mariner Hybrid 2.3L VIN H Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2009-2012 Mariner Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2006-2009 Milan 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2010-2011 Milan 2.5L Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 4 T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G Ford Global Part No. 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 303-638 303-630 303-630 Parts List & Operating Instructions Form No. 107267 Ford Tool Application Chart Year Model Engine Tool Description Part No. Ford American Part No. Ford Global Part No. 2010-2012 Milan Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2014 MKT 2.0L Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2012 MKX 2.0L VIN 9 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2013-2014 MKZ 2.0L Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 2006-2009 MKZ 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2010-2012 MKZ 2.5L VIN A Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2010-2012 MKZ Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2004 Monterey 3.9L VIN 6 Cam Sensor Synch Tool 6470 (511537) 2004-2007 Monterey 4.2L Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1997-2008 Mountaineer 4.0L SOHC VIN X Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 1997-2011 Mountaineer 4.0L SOHC V6 VIN E Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 1999-2002 Mountaineer 4.0L Push Rod V6 Cam Sensor Synch Tool 6483 (511551) 1997-2005 Mountaineer 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1996-1998 Mountaineer 5.0L V8 Cam Sensor Synch Tool 6469 (511536) T96T-1220-A 303-562 1999-2002 Mountaineer 5.0L V8 Cam Sensor Synch Tool 6470 (511537) 1996-1998 Mustang 3.8L V6 Cam Sensor Synch Tool 6469 (511536) 1999-2004 Mustang 3.8L V6 Cam Sensor Synch Tool 6470 (511537) 2005-2010 Mustang 4.0L SOHC VIN N Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 1997-2002 Mustang 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1996-2004 Mustang 4.6L VIN X Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 2003-2004 Mustang 4.6L VIN Y Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1994-2002 Mystique 2.0L 4 cyl. VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 1997-2002 Mystique 2.0L 4 cyl. VIN 3 Crankshaft TDC Timing Tool 6475 (511542) T97P-6000-A 303-574 1998-1999 Navigator 5.4L Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 1998-2002 Navigator 5.4L Cam Positioning Tool Cam Holding Tool 6476 (511543 & 4) 6477 (511545) T96T-6256-AR T96T-6256-B 303-S568 303-557 2001-2011 Ranger 2.3L VIN D Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 1995-1997 Ranger 3.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 303-630 303-638 303-630 T96T-12200-A 303-562 303-630 5 Parts List & Operating Instructions Ford Tool Application Chart Year Model Engine Tool Description Part No. Ford American Part No. Ford Global Part No. 1998-2008 Ranger 3.0L V6 Cam Sensor Synch Tool 6473 (511540) 1996-1998 Ranger 4.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1997-2011 Ranger 4.0L SOHC VIN E Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 1997-2008 Ranger 4.0L SOHC VIN X Cam Gear Holding Tool Crankshaft Holding Tool Cam Holding Tool Adapter Cam Holding Tool Cam Gear Holding Tool Adapter Timing Chain Tensioner Tool Cam Gear Bolt Socket & Extension 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4) T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 2003-2011 Ranger 4.0L SOHC Cam Gear Bolt Socket & Extension 6485 (511553 & 4) T97T-6256-F, -G 303-565, -575 1999-2000 Ranger 4.0L Push Rod Cam Sensor Synch Tool 6483 (511551) 1996-1997 Sable 3.0L V6 2V Cam Sensor Synch Tool 6472 (511539) 1998-2005 Sable 3.0L V6 VIN U Cam Sensor Synch Tool 6473 (511540) 1998-2006 Sable 3.0L V6 VIN Z Cam Sensor Synch Tool 6473 (511540) 2013-2014 Taurus 2.0L Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 1996-1997 Taurus 3.0L V6 2V Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1998-2005 Taurus 3.0L V6 VIN U Cam Sensor Synch Tool 6473 (511540) 1998-2006 Taurus 3.0L V6 VIN Z Cam Sensor Synch Tool 6473 (511540) 1997 Thunderbird 3.8L V6 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562 1997-2002 Town Car 4.6L VIN W Cam Positioning Tool Cam Positioning Tool 6009 (511532) 6020 (511555) T91P-6256-A T92P-6256-A 303-380 303-413 2010-2013 Transit 2.0L VIN N Cam Alignment Tool Crankshaft TDC Timing Pin 6474 (511541) 6475 (511542) T94P-6256-CH T97P-6000-A 303-465 303-574 1995-1997 Windstar 3.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1998-2003 Windstar 3.0L V6 VIN U Cam Sensor Synch Tool 6473 (511540) 1996-1998 Windstar 3.8L V6 Cam Sensor Synch Tool 6469 (511536) 1999-2003 Windstar 3.8L V6 Cam Sensor Synch Tool 6470 (511537) 2006-2009 Zephyr 2.3L VIN Z Cam Alignment Tool 6474 (511541) Get parts at OTCparts.com 6 303-589 303-638 T95T-12200-A 303-529 303-589 303-589 303-589 303-589 303-589 T96T-12200-A 303-562 303-630 T94P-6256-CH 303-465 Parts List & Operating Instructions Form No. 107267 511532 (6009) Ford Camshaft Positioning Tool Application: 1991 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis 1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline 1997 – 2002 5.4L Expedition 1997 – 2002 4.6L Expedition, Explorer, Crown Victoria, Grand Marquis, Town Car (VIN W) 1997 – 2004 4.6L F-150 (VIN 6) 1997 – 2010 4.6L F-150 (VIN W) 1997 – 1998 4.6L F-Series Truck same as 1997 – 2002 5.4L F-Series Truck Ford No. 303-380 1997 – 2005 4.6L Mountaineer (VIN W) (T91P-6256-A) 1997 – 2002 4.6L Mustang (VIN W) 1996 – 2004 4.6L Mustang (VIN X) 2003 – 2004 4.6L Mustang (VIN Y) 1998 – 1999 5.4L Navigator Note: The 1991 4.6L 2V V8 application does not require the use of tool No. 511555 (6020). CAUTION: To prevent damage to valves and pistons, do NOT rotate the crankshaft and/or camshaft(s) when removing timing chain(s) and installing cylinder heads. Because this is not a free-wheeling engine, if it has "jumped time," there will be damage to the valves and/or pistons, which will require the removal of the cylinder heads. The cam sprocket should be disassembled from the camshaft only when one of the components must be replaced. 1. Remove all necessary components to access the timing chains. 2. Rotate the engine to No. 1 TDC. 3. Assemble tools : • 1991 4.6L 2V V8 : Refer to Figure 1. Install No. 511532 (6009) on flats of the camshaft to prevent accidental rotation of the camshafts. • All other applications : Refer to Figure 2. Install No. 511532 (6009) and Cam Positioning Tool No. 511555 (6020) into each camshaft end before removing (or installing) timing chain tensioners and chains­—this prevents valve train damage. 4. Perform camshaft service as required. 5. Refer to the vehicle service manual for the correct camshaft-to-crankshaft timing procedure. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. No. 511532 (6009) Ford Camshaft Positioning Tool No. 511555 (6020) Ford Camshaft Positioning Tool Figure 1 The 1991 4.6L 2V V8 application does not require the use of tool No. 6020. Figure 2 All other applications. 7 Parts List & Operating Instructions 511555 (6020) Ford Camshaft Positioning Tool Application: 1992 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis 1997 – 2002 4.6L Crown Victoria, Expedition, Explorer Grand Marquis, Town Car (VIN W) 1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline 1997 – 2012 4.6L Econoline (VIN W) 1997 – 2002 5.4L Expedition 1997 – 2004 4.6L F-150 (VIN 6) 1997 – 2010 4.6L F-150 (VIN W) 1997 – 1998 4.6L F-Series Truck 1997 – 2002 5.4L F-Series Truck 1997 – 2005 4.6L Mountaineer (VIN W) 1997 – 2002 4.6L Mustang (VIN W) 1996 – 2004 4.6L Mustang (VIN X) 2003 – 2004 4.6L Mustang (VIN Y) 1998 – 1999 5.4L Navigator Note: Tool No. 511555 (6020; same as Ford No. 303-413/T92P-6256-A) must be used with tool No. 511532 (6009; same as Ford No. 303-380/T91P-6256-A). CAUTION: To prevent damage to valves and pistons, DO NOT rotate the crankshaft and/or camshaft(s) when removing the timing chain(s) and installing the cylinder heads. Because this is not a free-wheeling engine, if it has "jumped time" there will be damage to the valves and/or pistons, which will require the removal of the cylinder heads. The cam sprocket should be disassembled from the camshaft only when one of the components must be replaced. 1. Remove all necessary components to access the timing chains. 2. Rotate the engine to No. 1 top dead center. 3. Disassembly: Install Camshaft Positioning Tool (511555/6020) and Cam Positioning Tool (511532/6009) into each camshaft end, as shown, before removing timing chain tensioners and chains to prevent valve train damage. No. 511532 (6009) Ford Camshaft Positioning Tool 4. Assembly: Install Camshaft Positioning Tool No. 511555 (6020) (511555/6020) and Cam Positioning Tool Ford Camshaft (511532/6009) into each camshaft end, as shown, Positioning Tool before installing timing chains and tensioners to prevent valve train damage. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 8 Parts List & Operating Instructions Form No. 107267 511533 (6466) Ford Crankshaft Sensor Positioner Application: 1989 – 1997 Ford Ranger w/ 2.3L, 4 cyl., dual plug engine Note: Same as Ford No. 303-354 (T89P-6316-A). 1. Install Crankshaft Sensor Positioner No. 6466 (511533) on sensor as shown. No. 6466 (511533) 2. Rotate crankshaft so outer vane on crankshaft pulley hub assembly engages both sides of tool. Tighten sensor assembly retaining bolts to specifications. 3. Rotate crankshaft so vane on crankshaft pulley hub assembly is no longer engaged in tool. Remove tool. Outer vane of crankshaft pulley hub assembly. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511534 (6467) Ford Camshaft Sensor Synchronizer Tool Application: 1990 – 1997 3.8L V6 Thunderbird/Cougar 1989 – 1995 3.8L V6 Supercharged Thunderbird/Cougar 1994 – 1998 3.8L V6 Mustang 1998 3.8L V6 Windstar Note: Same as Ford No. 303-358 (T89P-12200-A). CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. The connector MUST be reassembled in the same position during installation. 1. Rotate crankshaft to set No. 1 cylinder at 26° after top dead center of the compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 6467 (511534). Camshaft Sensor Housing 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 9 Parts List & Operating Instructions 511535 (6468) Ford Camshaft Pulley Holding Tool Application: 1993 – 1997 Ford Probe w/ 2.0L, 4 cyl., engine Note: Same as Ford No. 303-398 (T92C-6256-AH). 1. Rotate engine to align camshaft timing marks with crankshaft timing marks. 2. Insert No. 6468 (511535) between intake and exhaust cam pulleys. The tool will fit correctly only one way. The side of tool marked UP must be facing the technician and top of engine. 3. Follow vehicle service manual procedure to service timing belt as required. Remove tool when finished. No. 6468 (511535) WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511536 (6469) Ford Camshaft Sensor Synchronizer Tool Application: 1997 1997 – 2008 1996 – 1998 2004 – 2007 1996 – 1998 3.8L V6 Cougar, Thunderbird 4.2L V6 Econoline, F-Series Truck 5.0L V8 Ford Explorer, Mercury Mountaineer 4.2L Freestar, Monterey 3.8L V6 Mustang, Windstar Note: Same as Ford No. 303-562 (T96T-12200-A). CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. To prevent equipment damage, the connector MUST be reassembled in the same position during installation. No. 511536 (6469) Camshaft Sensor Housing 1. Rotate crankshaft to set No. 1 cylinder at top dead center of the compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 511536 (6469). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. 10 WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions Form No. 107267 511537 (6470) Ford Camshaft Sensor Synchronizer Tool Application: 1999 – 2002 2004 – 2007 2004 1999 – 2004 1999 – 2003 5.0L V8 Explorer, Mountaineer 3.9L Freestar (VIN 6) 3.9L Monterey (VIN 6) 3.8L V6 Mustang 3.8L V6 Windstar No. 511537 (6470) Note: Same as Ford No. 303-630. CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. To prevent equipment damage, the connector MUST be reassembled in the same position during installation. Camshaft Sensor Housing 1. Rotate crankshaft to set No. 1 cylinder at top dead center of compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 511537 (6470). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511538 (6471) Ford Camshaft Sensor Synchronizer Tool Application: 1993 – 1995 3.0L V6 Ford Taurus/Mercury Sable Note: Same as Ford No. 303-453 (T93P-12200-A). No. 6471 (511538) CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. The connector MUST be reassembled in the same position during installation. 1. Rotate crankshaft to set No. 1 cylinder at top dead center of compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 6471 (511538). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. Camshaft Sensor Housing WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 11 Parts List & Operating Instructions 511539 (6472) Ford Camshaft Positioning Tool Set Application: 1995 – 1997 3.0L V6 Aerostar, Ranger, Windstar 1996 – 1998 4.0L V6 Aerostar, Explorer, Ranger 1996 – 1997 3.0L V6 2V Sable, Taurus CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. To prevent equipment damage, the connector MUST be reassembled in the same position during installation. No. 511539 (6472) 511539 1. Rotate crankshaft to set No. 1 cylinder at TDC of compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 511539 (6472). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511540 (6473) Ford Camshaft Sensor Synchronizer Tool Application: 1998 – 2008 1998 – 2005 1998 – 2006 1998 – 2003 3.0L V6 Ranger 3.0L V6 Sable, Taurus (VIN U) 3.0L V6 Sable, Taurus (VIN Z) 3.0L V6 Windstar Note: Same as Ford No. 303-589. CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. To prevent equipment damage, the connector MUST be reassembled in the same position during installation. 1. Rotate crankshaft to set No. 1 cylinder at top dead center of compression stroke. No. 511540 (6473) Camshaft Sensor Housing 2. Engage camshaft sensor housing vane in slot of tool No. 511540 (6473). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. 12 WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions Form No. 107267 511541 (6474) Ford Camshaft Alignment Tool Application: 1994 – 2002 1999 – 2002 2012 – 2014 2001 – 2004 2013 – 2014 2005 – 2008 2009 – 2014 2005 – 2008 2009 – 2012 2012 – 2014 2000 – 2004 2002 – 2004 2005 – 2012 2003 – 2007 2006 – 2009 2010 – 2014 2010 – 2014 2009 – 2012 2010 – 2011 2010 – 2012 2014 2012 2010 – 2012 2001 – 2011 2010 – 2013 2.0L 4 cyl. Contour, Mystique (VIN 3) 2.0L Cougar (VIN 3) 2.0L Edge, Explorer (VIN 9) 2.0L Escape (VIN B) 2.0L Escape (VIN 9), Fusion, MKZ, Taurus 2.3L Escape, Mariner (VIN Z) 2.5L Escape (VIN 7) 2.3L Escape Hybrid, Mariner Hybrid (VIN H) 2.5L Escape Hybrid, Mariner Hybrid (VIN 3) 2.0L Focus (VIN 2) 2.0L Focus (VIN 3) 2.0L Focus (VIN 5) 2.0L Focus (VIN N) 2.3L Focus (VIN Z) 2.3L Fusion, Milan, MKZ, Zephyr (VIN Z) 2.5L Fusion (VIN A) 2.5L Fusion Hybrid (VIN 3) 2.5L Mariner (VIN 7) 2.5L Milan 2.5L Milan Hybrid, MKZ Hybrid (VIN 3) 2.0L MKT 2.0L MKX (VIN 9) 2.5L MKZ (VIN A) 2.3L Ranger (VIN D) 2.0L Transit (VIN N) CAUTION: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent rotation can result in engine damage. Note: • Same as Ford No. 303-465 (T94P-6256-CH). • The camshaft timing slots are offset. If the camshaft alignment timing tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts. 1. Rotate engine to top dead center on the No. 1 cylinder. 2. Align camshafts by installing tool No. 511541 (6474) into the slots at the rear of the camshafts as shown. 3. Service the timing belt as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. 5. Remove the tool. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. No. 511541 (6474) 13 Parts List & Operating Instructions 511542 (6475) Ford Crankshaft TDC Timing Pin Application: 1997 – 2002 2.0L 4 cyl. Contour, Mystique (VIN 3) 1999 – 2002 2.0L Cougar (VIN 3) 2012 – 2014 2.0L Edge, Explorer (VIN 9) 2001 – 2004 2.0L Escape (VIN B) 2013 – 2014 2.0L Escape (VIN 9), Fusion, MKZ, Taurus 2012 – 2014 2.0L Focus (VIN 2) 2000 – 2004 2.0L Focus (VIN 3) 2002 – 2004 2.0L Focus (VIN 5) 2005 – 2011 2.0L Focus (VIN N) 2014 2.0L MKT 2010 – 2012 2.0L Transit (VIN N) CAUTION: To prevent damage to the engine, remove the No. 511542 (6475) timing pin from the engine and reinstall the access plug BEFORE cranking the engine. 1. Rotate crankshaft to set No. 1 cylinder on TDC of compression stroke. 2. Remove the access plug from the engine and install tool No. 511542 (6475) timing pin as shown. (The pin will completely thread into the hole when the engine is at TDC on the No. 1 cylinder.) 3. Service the timing belt as required according to vehicle service manual procedures. 4. Torque fasteners to factory specifications. No. 6475 (511542) 14 WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions Form No. 107267 511543 / 511544 (6476) Ford Camshaft Positioning Tool Set Application: 511543 511544 1997 – 2002 1997 – 2002 1997 – 2002 1998 – 2002 4.6L Econoline, F-Series Truck (VIN W) 5.4L Econoline, Expedition, F-Series Truck 6.8L V10 Econoline 5.4L Navigator 2-Hole Note: • 511543 is the same as Ford No. 303-569 (T96T-6256-AR1) and 511544 is the same as Ford No. 303-570 (T96T-6256-AR2). • This tool is used with No. 6477 (511545) Ford Camshaft Holding Tool. 1. Two-hole Camshaft Sprocket: Use No. 511543 to position the camshaft sprocket (2-hole) on the engine as shown. 18 mm Hex Hd. Camshaft Sprocket: Use No. 511543 with No. 511544 to position the camshaft sprocket (18 mm hex hd.) on the engine as shown. 2. Service the timing chain as required according to procedures in the vehicle service manual. 3. Torque the fasteners to factory specifications. Camshaft Sprocket 18 mm Hex Hd. Camshaft Sprocket No. 511543 No. 511544 No. 511543 WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511545 (6477) Ford Camshaft Holding Tool Application: No. 6477 (511545) 1997 – 2009 1997 – 2002 1997 – 2002 1998 – 2002 4.6L Econoline, F-Series Truck (VIN W) 5.4L Econoline (V8), Expedition, F-Series Truck 6.8L V10 Econoline 5.4L V8 Navigator Note: • Same as Ford No. 303-557 (T96T-6256-B). • This tool is used with No. 6476 (511543 & 511544) Ford Camshaft Positioning Tool Set. 1. Install tool No. 511545 (6477) on the camshaft as shown. 2. Torque hex hd. bolts at 20 ft.•lbs. to ensure correct clamping force. Note: Each bolt must be engaged by the same number of threads in the bottom clamp to ensure correct clamp alignment. 3. Repair the engine as required according to instructions in the vehicle service manual. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 15 Parts List & Operating Instructions 511546 (6478) Ford Camshaft Gear Holding Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) No. 511546 (6478) No. 511550 (6482) 1. Install tool Nos. 511546 (6478) and 511550 (6482) on the camshaft as shown. 2. Secure tool No. 511546 (6478) to the cylinder head. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511547 (6479) Ford Crankshaft Holding Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: Same as Ford No. 303-573 (T97T-6303-A). 1. Install tool No. 511547 (6479) on the crankshaft damper. 2. Rotate the engine counterclockwise (CCW) until the tool stops against the engine block. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 16 No. 511547 (6479) Parts List & Operating Instructions Form No. 107267 511548 (6480) Ford Camshaft Holding Tool Adapter Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: No. 511549 • Same as Ford No. 303-576 (T97T-6256-D). (6481) • This tool is used with No. 511549 (6481) Ford Camshaft Holding Tool. No. 511548 (6480) 1. Install tool Nos. 511548 (6480) and 511549 (6481) on the camshaft as shown. 2. Secure tool No. 511549 (6481) to the cylinder head. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511549 (6481) Ford Camshaft Holding Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: • Same as Ford No. 303-577 (T97T-6256-C). • This tool is used with No. 511548 (6480) Ford Camshaft Holding Tool Adapter. No. 511549 (6481) No. 511548 (6480) 1. Install tool Nos. 511548 (6480) and 511549 (6481) on the camshaft as shown. 2. Secure tool No. 511549 (6481) to the cylinder head. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 17 Parts List & Operating Instructions 511550 (6482) Ford Camshaft Holding Tool Adapter Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: • Same as Ford No. 303-578 (T97T-6256-A). • This tool is used with No. 511546 (6478) Ford Camshaft Gear Holding Tool . 1. Install tool Nos. 511546 (6478) and 511550 (6482) on the camshaft as shown. 2. Secure tool No. 511546 (6478) to the cylinder head. No. 511546 (6478) 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners according to factory specifications. No. 511550 (6482) WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511551 (6483) Ford Camshaft Synchronizer Tool Application: 1999 – 2002 4.0L Push Rod Explorer, Mountaineer 1999 – 2000 4.0L Push Rod Ranger Note: Same as Ford No. 303-638. CAUTION: Before removing the camshaft sensor housing assembly, note the position of the camshaft sensor electrical connector. To prevent equipment damage, the connector MUST be reassembled in the same position during installation. No. 511551 (6483) Camshaft Sensor Housing 1. Rotate crankshaft to set No. 1 cylinder at top dead center of compression stroke. 2. Engage camshaft sensor housing vane in slot of tool No. 511551 (6483). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. 5. Torque fasteners to factory specifications. 18 WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions Form No. 107267 511552 (6484) Ford Timing Chain Tensioner Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: Same as Ford No. 303-571 (T97T-6K254-A). 1. Remove the hydraulic chain tensioner from the engine. 2. Install tool No. 511552 (6484) into the engine to hold pressure on the timing chain during the cam timing procedure. 3. Adjust camshaft timing according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. No. 511552 (6484) WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 511553 / 511554 (6485) Ford Camshaft Gear Bolt Socket Extension Application: 1997 – 2011 1997 – 2008 2005 – 2010 2003 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 4.0L SOHC Mustang (VIN N) 4.0L SOHC Ranger Note: 511553 is the same as Ford No. 303-565 (T97T-6256-G) and 511554 is the same as Ford No. 303-575 (T97T-6256-F). No. 6485 (511553 & 511554) No. 511554 Extension No. 511553 Camshaft Gear Bolt Socket 1. Assemble the No. 6485 (511553 & 511554) socket and extension on the camshaft gear bolt as shown. Removal: Use a ratchet or breaker bar to loosen and remove the bolt from the camshaft. Assembly: Use a torque wrench to tighten the bolt on the camshaft. Refer to the vehicle service manual for the correct torque specifications. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 19 655 Eisenhower Drive Owatonna, MN 55060 USA Phone: (507) 455-7000 Tech. Serv.: (800) 533-6127 Fax: (800) 955-8329 Order Entry: (800) 533-6127 Fax: (800) 283-8665 International Sales: (507) 455-7223 Fax: (507) 455-7063 Website: www.otctools.com Form No. 107267 Issue Date: January 12, 2015 Rev. E © Bosch Automotive Service Solutions Inc.