Ford - Mountaineer - Parts Catalogue - 1999 - 2002

Parts List & Operating Instructions for No. 6489 Master Service Set for Ford Cam and Valve Train Repair 6009 6020 6466 6467 6468 6469 6470 6471 6472 6473 6474 6475 6476 6477 6478 6479 6480 6481 6482 6483 6484 6485 Form No. 107267 Sheet 1 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 1 of 7, Back Ford Tool Application Chart Year Make & Model Engine 1995-1997 1996-1998 1994-2002 1997-2002 1991-1998 1992-1998 1997-2002 1997-1998 Aerostar Aerostar Contour Contour Crown Victoria Crown Victoria Econoline Econoline 3.0L V6 4.0L V6 2.0L 4 cyl. DOHC Zetec 2.0L 4 cyl. DOHC Zetec 4.6L 2V V8 4.6L 2V V8 4.2L V6 4.6L & 5.4L V8, 6.8L V10 1997-2002 1997-2002 1997-2002 Econoline Econoline Econoline 4.6L & 5.4L 5.4L V8 6.8L V10 1997-2002 1997-1998 Econoline Expedition Windsor V8 5.4L V8 1997-2002 Expedition 5.4L V8 1996-1998 1997-2002 Explorer Explorer 1999-2002 1996-1998 1999-2002 1997-2002 1997-1998 Explorer Explorer Explorer F-Series Truck F-Series Truck 1997-2002 1997-2002 1997-2002 1994-1995 1996-1998 1999-2002 1993-1997 1989-1997 1995-1997 1998-2002 1996-1998 1993-1995 1996-1997 1998-2002 1989-1995 1990-1995 1997 1995-1997 1998-2002 1995 1996-1998 1999-2002 1998 F-Series Truck F-Series Truck F-Series Truck Mustang Mustang Mustang Probe Ranger Ranger Ranger Ranger Taurus Taurus Taurus Thunderbird Thunderbird Thunderbird Windstar Windstar Windstar Windstar Windstar Lincoln Navigator 4.6L & 5.4L 5.4L V8 Windsor V8 3.8L V6 3.8L V6 3.8L V6 2.0L 4 cyl. 2.3L, 4 cyl. dual plug 3.0L V6 3.0L V6 4.0L V6 3.0L V6 3.0L V6 2-valve 3.0L V6 Supercharged 3.8L V6 3.8L V6 3.8L V6 3.0L V6 3.0L V6 3.8L V6 3.8L V6 3.8L V6 5.4L V8 1998-2002 Lincoln Navigator 5.4L V8 1989-1995 1990-1995 1997 1991-1998 1992-1998 1997-2002 Cougar Cougar Cougar Grand Marquis Grand Marquis Mountaineer Supercharged 3.8L V6 3.8L V6 3.8L V6 4.6L 2V V8 4.6L 2V V8 4.0L SOHC V6 1999-2002 1996-1998 1999-2002 1994-2002 1997-2002 1993-1995 1996-1997 1998-2002 Mountaineer Mountaineer Mountaineer Mystique Mystique Sable Sable Sable 4.0L Push Rod V6 5.0L V8 5.0L V8 2.0L 4 cyl. DOHC Zetec 2.0L 4 cyl. DOHC Zetec 3.0L V6 3.0L V6 2-valve 3.0L V6 4.0L V6 4.0L SOHC V6 4.0L Push Rod V6 5.0L V8 5.0L V8 4.2L V6 4.6L & 5.4L V8 Tool Description Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Alignment Tool Crankshaft TDC Timing Pin Cam Positioning Tool Cam Positioning Tool Cam Sensor Synch Tool Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool Set Cam Holding Tool Cam Positioning Tool Set Cam Holding Tool Cam Holding Tool Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool Set Cam Holding Tool Cam Sensor Synch Tool 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 & Ext. Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool Set Cam Holding Tool Cam Holding Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Pulley Holding Tool Crankshaft Sensor Positioner Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Positioning Tool Cam Positioning Tool Cam Positioning Tool Set Cam Holding Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Positioning Tool Cam Positioning Tool 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 & Ext. Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Alignment Tool Crankshaft TDC Timing Pin Cam Sensor Synch Tool Cam Sensor Synch Tool Cam Sensor Synch Tool Part No. 6472 (511539) 6472 (511539) 6474 (511541) 6475 (511542) 6009 (511532) 6020 (511555) 6469 (511536) 6009 (511532) 6020 (511555) 6476 (511543 & -4) 6477 (511545) 6476 (511543 & -4) 6477 (511545) 6477 (511545) 6009 (511532) 6020 (511555) 6476 (511543 & -4) 6477 (511545) 6472 (511539) 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & -4) 6483 (511551) 6469 (511536) 6470 (511537) 6469 (511536) 6009 (511532) 6020 (511555) 6476 (511543 & -4) 6477 (511545) 6477 (511545) 6467 (511534) 6469 (511536) 6470 (511537) 6468 (511535) 6466 (511533) 6472 (511539) 6473 (511540) 6472 (511539) 6471 (511538) 6472 (511539) 6473 (511540) 6467 (511534) 6467 (511534) 6469 (511536) 6472 (511539) 6473 (511540) 6467 (511534) 6469 (511536) 6470 (511537) 6009 (511532) 6020 (511555) 6476 (511543 & -4) 6477 (511545) 6467 (511534) 6467 (511534) 6469 (511536) 6009 (511532) 6020 (511555) 6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & -4) 6483 (511551) 6469 (511536) 6470 (511537) 6474 (511541) 6475 (511542) 6471 (511538) 6472 (511539) 6473 (511540) Ford No. American Part No. T95T-12200-A T95T-12200-A T94P-6256-CH T97P-6000-A T91P-6256-A T92P-6256-A T96T-12200-A T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B T96T-6256-AR T96T-6256-B T96T-6256-B T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B T95T-12200-A T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G T96T-12200-A T96T-12200-A T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B T96T-6256-B T89P-12200-A T96T-12200-A T92C-6256-AH T89P-6316-A T95T-12200-A T95T-12200-A T93P-12200-A T95T-12200-A T89P-12200-A T89P-12200-A T96T-12200-A T95T-12200-A T89P-12200-A T96T-12200-A T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B T89P-12200-A T89P-12200-A T96T-12200-A T91P-6256-A T92P-6256-A T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G T96T-12200-A T94P-6256-CH T97P-6000-A T93P-12200-A T95T-12200-A Ford Global Part No. 303-529 303-529 303-465 303-574 303-380 303-413 303-562 303-380 303-413 303-S568 303-557 303-S568 303-557 303-557 303-380 303-413 303-S568 303-557 303-529 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 303-638 303-562 303-630 303-562 303-380 303-413 303-S568 303-557 303-557 303-358 303-562 303-630 303-398 303-354 303-529 303-589 303-529 303-453 303-529 303-589 303-358 303-358 303-562 303-529 303-589 303-358 303-562 303-630 303-380 303-413 303-S568 303-557 303-358 303-358 303-562 303-380 303-413 303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575 303-638 303-562 303-630 303-465 303-574 303-453 303-529 303-589 Parts List & Operating Instructions 6009 Ford Camshaft Positioning Tool Application: 1991 – 1998 1997 – 1998 1997 – 1998 1998 1997 – 1998 4.6L 2V V8 Crown Victoria, Grand Marquis 4.6L & 5.4L V8, 6.8L V10 Econoline 4.6L & 5.4L V8 F-Series Truck 5.4L V8 Navigator 5.4L V8 Expedition No. 6009 NOTE: Same as Ford No. 303-380 (T91P-6256-A). (511532) 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 TDC. 3. Install the No. 6009 (511532) on flats of the camshaft as shown to prevent accidental rotation of the camshafts. 4. Perform camshaft service as required. 5. Refer to the vehicle service manual for the correct camshaft-to-crankshaft timing procedure. 6020 Ford Camshaft Positioning Tool Application: 1992 – 1998 4.6L 2V V8 Crown Victoria, Grand Marquis 1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline 1997 – 1998 4.6L & 5.4L V8 F-Series Truck No. 6009 (511532) 1998 5.4L V8 Navigator Ford Camshaft 1997 – 1998 5.4L V8 Expedition Positioning Tool NOTE: Tool No. 6020 (511555) (same as Ford No. 303-413/T92P6256-A) must be used with tool No. 6009 (511532) (same as Ford No. 303-380/T91P-6256-A). No. 6020 (511555) Ford Camshaft Positioning Tool 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 (6020/511555) and Cam Positioning Tool (6009/511532) into each camshaft end, as shown, before removing timing chain tensioners and chains to prevent valve train damage. 4. Assembly: Install Camshaft Positioning Tool (6020/511555) and Cam Positioning Tool (6009/511532) into each camshaft end, as shown, before installing timing chains and tensioners to prevent valve train damage. Form No. 107267 Sheet 2 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 2 of 7, Back 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) l 2. Rotate crankshaft so outer vane on crankshaft pulley hub assembly engages both sides of tool. Tighten sensor assembly retaining bolts to specifications. l 3. Rotate crankshaft so vane on crankshaft pulley hub assembly is no longer engaged in tool. Remove tool. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Outer vane of crankshaft pulley hub assembly. 6467 Ford Camshaft Sensor Synchronizer Tool Application: 1990 – 1995 1989 – 1995 1994 – 1995 1995 3.8L V6 Thunderbird/Cougar 3.8L V6 Supercharged Thunderbird/Cougar 3.8L V6 Mustang 3.8L V6 Windstar NOTE: Same as Ford No. 303-358 (T89P-12200-A). l Important: 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. Camshaft Sensor Housing 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). 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. Parts List & Operating Instructions 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. 6469 Ford Camshaft Sensor Synchronizer Tool Application: 1996 – 1998 3.8L V6 Mustang, Windstar 1997 3.8L V6 Thunderbird/Cougar 1997 – 2002 4.2L V6 Econoline, F-Series Truck 1996 – 1998 5.0L V8 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-562 (T96T-12200-A). Important: 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. No. 6469 (511536) 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. 6469 (511536). 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. Form No. 107267 Sheet 3 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 3 of 7, Back 6470 Ford Camshaft Sensor Synchronizer Tool Application: 1999 – 2002 3.8L V6 Mustang, Windstar 1999 – 2002 5.0L V8 Ford Explorer, Mercury Mountaineer No. 6470 (511537) NOTE: Same as Ford No. 303-630. Important: 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. 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. 6470 (511537). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. 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). Important: 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. No. 6471 (511538) Camshaft Sensor Housing WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions 6472 Ford Camshaft Sensor Synchronizer Tool Application: 1995 – 1997 3.0L, V6 Windstar, Aerostar, Ranger 1996 – 1997 3.0L, 2-valve V6 Ford Taurus/Mercury Sable 1996 – 1998 4.0L, V6 Aerostar, Ranger, Explorer No. 6472 (511539) NOTE: Same as Ford No. 303-529 (T95T-12200-A). Important: 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. 6472 (511539). 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. 6473 Ford Camshaft Sensor Synchronizer Tool Application:1998 – 2002 3.0L V6 Mercury Sable/Ford Taurus, Ranger, Windstar NOTE: Same as Ford No. 303-589. No. 6473 (511540) Important: 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. 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. 6473 (511540). 3. Rotate tool on camshaft sensor housing until tool engages housing notch. (Tool should be square and in contact with entire top of housing.) WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 4. Install camshaft sensor housing and tool assembly into engine according to instructions in the vehicle service manual. Torque fasteners to factory specifications. Form No. 107267 Sheet 4 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 4 of 7, Back 6474 Ford Camshaft Alignment Tool Application: 1994 – 2002 Ford Contour/Mercury Mystique w/ 2.0L, 4 cyl., DOHC Zetec Engine NOTE: Same as Ford No. 303-465 (T94P-6256-CH). 1. Rotate engine to top dead center on the No. 1 cylinder. 2. Align camshafts by installing tool No. 6474 (511541) 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. No. 6474 (511541) 4. Torque fasteners specifications. to factory 5. Remove the tool. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 6475 Ford Crankshaft TDC Timing Pin Application: 1997 – 2002 Ford Contour/Mercury Mystique w/ 2.0L 4 cyl. DOHC Zetec engine w/ variable cam timing NOTE: Same as Ford No. 303-574 (T97P-6000-A). No. 6475 (511542) 1. Rotate crankshaft to set No. 1 cylinder on top dead center of compression stroke. 2. Remove the access plug from the engine, and install No. 6475 (511542) 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. IMPORTANT: To prevent damage to the engine, remove the No. 6475 (511542) timing pin from the engine and reinstall the access plug BEFORE cranking the engine. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions 6476 Ford Camshaft Positioning Tool Set Application: 1997 – 2002 1997 – 2002 1998 – 2002 1997 – 2002 No. 511543 2-Hole Camshaft Sprocket 4.6L & 5.4L Econoline, F-Series Truck 5.4L V8 Ford Expedition 5.4L V8 Lincoln Navigator 6.8L V10 Econoline Note: This tool is used with No. 6477 (511545) Ford Camshaft Holding Tool. 18 mm Hex Hd. Camshaft Sprocket 1. Two-hole Camshaft Sprocket: Use tool No. 511543 to position camshaft sprocket (2-hole) on the engine as shown. No. 511544 18mm Camshaft Sprocket: Use tool No. 511543 with tool No. 511544 to position camshaft sprocket (18 mm hex hd.) on the engine as shown. No. 511543 2. Service the timing chain as required according to procedures in the vehicle service manual. 511543 511544 NOTE: 511543 is the same as Ford No. 303-569 (T96T-6256AR1) and 511544 is the same as Ford No. 303-570 (T96T6256-AR2). WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 3. Torque fasteners to factory specifications. 6477 Ford Camshaft Holding Tool Application: 1997 – 2002 1997 – 2002 1997 – 2002 1998 – 2002 No. 6477 (511545) 4.6L Windsor V8 Econoline, F-Series Truck 5.4L V8 Econoline, Expedition, F-Series Truck 6.8L V10 Econoline 5.4L V8 Lincoln Navigator NOTE: Same as Ford No. 303-557 (T96T-6256-B). Note: This tool is used with No. 6476 (511543 & 511544) Ford Camshaft Positioning Tool Set. 1. Install tool No. 6477 (511545) 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. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 3. Repair the engine as required according to instructions in the vehicle service manual. Form No. 107267 Sheet 5 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 5 of 7, Back 6478 Ford Camshaft Gear Holding Tool Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer l NOTE: Same as Ford No. 303-564 (T97T-6256-B). l No. 6478 (511546) Note: This tool is used with No. 6482 (511550) Ford Camshaft Gear Holding Tool Adapter. No. 6482 (511550) 1. Install tool Nos. 6478 (511546) and 6482 (511550) on the camshaft as shown. 2. Secure tool No. 6478 (511546) to the cylinder head. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners to factory specifications. 6479 Ford Crankshaft Holding Tool Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-573 (T97T-6303-A). No. 6479 (511547) 1. Install tool No. 6479 (511547) 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. l Parts List & Operating Instructions 6480 Ford Camshaft Holding Tool Adapter Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-576 (T97T-6256-D). No. 6481 (511549) Note: This tool is used with No. 6481 (511549) Ford Camshaft Holding Tool. No. 6480 (511548) 1. Install tool Nos. 6480 (511548) and 6481 (511549) on the camshaft as shown. 2. Secure tool No. 6481 (511549) 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. 6481 Ford Camshaft Holding Tool Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer No. 6481 (511549) NOTE: Same as Ford No. 303-577 (T97T-6256-C). No. 6480 (511548) Note: This tool is used with No. 6480 (511548) Ford Camshaft Holding Tool Adapter. 1. Install tool Nos. 6480 (511548) and 6481 (511549) on the camshaft as shown. 2. Secure tool No. 6481 (511549) 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. Form No. 107267 Sheet 6 of 7 Issue Date: 11/20/02 Rev. B Parts List & Operating Instructions Form No. 107267, Sheet 6 of 7, Back 6482 Ford Camshaft Gear Holding Tool Adapter Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-578 (T97T-6256-A). l l No. 6478 (511546) Note: This tool is used with No. 6478 (511546) Ford Camshaft Gear Holding Tool . No. 6482 (511550) 1. Install tool Nos. 6478 (511546) and 6482 (511550) on the camshaft as shown. 2. Secure tool No. 6478 (511546) to the cylinder head. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. 3. Service the timing chain as required according to instructions in the vehicle service manual. 4. Torque fasteners according to factory specifications. 6483 Ford Camshaft Sensor Synchronizer Tool Application: 1999 – 2002 4.0L Push Rod V6 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-638. Important: 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. No. 6483 (511551) 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. 6483 (511551). 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. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Parts List & Operating Instructions 6484 Ford Timing Chain Tensioner Tool Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer NOTE: Same as Ford No. 303-571 (T97T-6K254-A). 1. Remove the hydraulic chain tensioner from the engine. 2. Install tool No. 6484 (511552) 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. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. No. 6484 (511552) 6485 Ford Camshaft Gear Bolt Socket & Extension Application: 1997 – 2002 4.0L SOHC V6 Ford Explorer, Mercury Mountaineer NOTE: 511553 is the same as Ford No. 303-565 (T97T-6256G) and 511554 is the same as Ford No. 303-575 (T97T6256-F). No. 6485 (511553 & 511554) No. 511553 Camshaft Gear Bolt Socket No. 511554 Extension 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. WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards. Assembly: Use a torque wrench to tighten the bolt on the camshaft. Refer to the vehicle service manual for the correct torque specifications. Form No. 107267 Sheet 7 of 7 Issue Date: 11/20/02 Rev. B