P0340 - May need Camshaft Synchronizer - Can I cheat and just replace the sensor?

[Get Forked]

Background:

1998 Ford Explorer with 201k miles. Purchased from a neighbor for $200 because he couldn't get it to pass emission.

Has code P0340. It runs pretty good. No issues starting or with drivability.

Pulled off the sensor and it is mangled on the inside. Looks like the synchronizer itself may be off balance (at least from what I have read) and tore up the sensor. Basically it fell apart. See picture. New on left old on right.

I cannot install the new sensor on top of the balancer. It will not fit. If you look at the picture of the top of my balancer, you can see that the C shaped metal part that comes up to send the signal to the sensor itself appears to be bent inwards.

Its 'C' shaped, but the corners appear to be pulled in. I don't think this is stock.

Problem is I cannot tell for sure what its supposed to look like. There appear to be multiple balancers and multiple designs from all the images I've searched.

Could I potentially bend out the corners of the balancer to have the sensor fit and shave down some of the plastic on the sensor itself to limit areas where it could potentially contact? It may wabble, but it could still send a signal correct?

I realise this is the lazy and not correct way to fix this, but keep in mind this is a $200 vehicle and I am just trying to get this thing to limp by.

Sure the rigged setup may not clear the P0340 code, but then again it may.

Just wondering if anyone has gotten around replacing the synchronizer when it probably should be replaced.

 

[Turdle]

You will need a new drive unit. Don't use inexpensive replacements.
I do have a tip. Since you need the tool, rotate the engine until the tool fits old sensor. Do not disturb engine, remove old unit, drop new unit in with tool attached. Should be set.

Careful as you remove the unit from the block.

Popping it loose is ok, after that pull straight up slowly so oil pump drive shaft stays down in the oil pump.

 

[Get Forked]

You will need a new drive unit. Don't use inexpensive replacements.
I do have a tip. Since you need the tool, rotate the engine until the tool fits old sensor. Do not disturb engine, remove old unit, drop new unit in with tool attached. Should be set.

Careful as you remove the unit from the block.

Popping it loose is ok, after that pull straight up slowly so oil pump drive shaft stays down in the oil pump.

So if I am careful with this and align the tool, finding TDC the old fashioned way is not necessary? Is that correct?

 

[Turdle]

As long as it was set correctly in the first place yes.

 

[410Fortune]

You have to get the new synchronIer installed on the same gear if the camshaft with the flag pointed in the same direction it was on the one you removed.
A couple of simple Marks with a sharpie can ensure you do.

When you drop the new synchro in, just like a distributor, they can only be installed at like 15 degree increments, so it’s pretty easy to get it on the same tooth… a little harder on the ohv 4.0 with its synchro on the back of the engine. You can get some room to work back there by unbolting the two 19mm trans mount nuts and jack up the back of the trans till it hits the floor