OTC 6489 Operating Instructions Manual

Parts List & Operating Instructions for

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)

Ford Tool Application Chart

Ford

Year Model Engine Tool Description Part No.

American

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

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

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

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

2012-2014 Edge 2.0L VIN 9 Cam Alignment Tool

Crankshaft TDC Timing Pin

2001-2004 Escape 2.0L VIN B Cam Alignment Tool

Crankshaft TDC Timing Pin

2013-2014 Escape 2.0L VIN 9 Cam Alignment Tool

Crankshaft TDC Timing Pin

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

1997-2002 Expedition 5.4L Cam Positioning Tool

Cam Positioning Tool Cam Positioning Tool Cam Holding Tool

2012-2014 Explorer 2.0L VIN 9 Cam Alignment Tool

Crankshaft TDC Timing Pin

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

6474 (511541) 6475 (511542)

6009 (511532) 6020 (511555)

6476 (511543 & 4) 6477 (511545)

6474 (511541) 6475 (511542)

6009 (511532) 6020 (511555)

6009 (511532) 6020 (511555) 6476 (511543 & 4) 6477 (511545)

6474 (511541) 6475 (511542)

6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4)

T94P-6256-CH T97P-6000-A

T91P-6256-A T92P-6256-A

T96T-6256-AR T96T-6256-B

T94P-6256-CH T97P-6000-A

T91P-6256-A T92P-6256-A

T91P-6256-A T92P-6256-A T96T-6256-AR T96T-6256-B

T94P-6256-CH T97P-6000-A

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.

303-465 303-574

303-380 303-413

303-S568 303-557

303-465 303-574

303-380 303-413

303-380 303-413 303-S568 303-557

303-465 303-574

303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575

Parts List & Operating Instructions

Ford Tool Application Chart

Ford

Year Model Engine Tool Description Part No.

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

1999-2002 Explorer 4.0L Push Rod V6 Cam Sensor Synch Tool 6483 (511551) 303-638

1997-2002 Explorer 4.6L VIN W Cam Positioning Tool

Cam Positioning Tool

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) 303-630

1997-2004 F-150 4.6L VIN 6 Cam Positioning Tool

Cam Positioning Tool

1997-2010 F-150 4.6L VIN W Cam Positioning Tool

Cam Positioning Tool

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

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

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

2000-2004 Focus 2.0L VIN 3 Cam Alignment Tool

Crankshaft TDC Timing Pin

2002-2004 Focus 2.0L VIN 5 Cam Alignment Tool

Crankshaft TDC Timing Pin

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) 303-630

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

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

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

6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4)

6009 (511532) 6020 (511555)

6009 (511532) 6476 (511543 & 4) 6020 (511555)

6474 (511541) 6475 (511542)

6009 (511532) 6020 (511555)

T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G

T91P-6256-A T92P-6256-A

T91P-6256-A T96T-6256-AR T92P-6256-A

T94P-6256-CH T97P-6000-A

T91P-6256-A T92P-6256-A

Ford

Global Part

No.

303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575

303-380 303-413

303-380 303-S568 303-413

303-465 303-574

303-380 303-413

Parts List & Operating Instructions Form No. 107267

Ford Tool Application Chart

Year Model Engine Tool Description Part No.

Ford

American

Ford

Global Part

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

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

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) 303-630

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

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

1999-2002 Mountaineer 4.0L Push Rod V6 Cam Sensor Synch Tool 6483 (511551) 303-638

1997-2005 Mountaineer 4.6L VIN W Cam Positioning Tool

Cam Positioning Tool

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) 303-630

1996-1998 Mustang 3.8L V6 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562

1999-2004 Mustang 3.8L V6 Cam Sensor Synch Tool 6470 (511537) 303-630

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

1997-2002 Mustang 4.6L VIN W Cam Positioning Tool

Cam Positioning Tool

1996-2004 Mustang 4.6L VIN X Cam Positioning Tool

Cam Positioning Tool

2003-2004 Mustang 4.6L VIN Y Cam Positioning Tool

Cam Positioning Tool

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

1998-2002 Navigator 5.4L Cam Positioning Tool

Cam Holding Tool

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

6474 (511541) 6475 (511542)

6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4)

6009 (511532) 6020 (511555)

6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4)

6009 (511532) 6020 (511555)

6476 (511543 & 4) 6477 (511545)

T94P-6256-CH T97P-6000-A

T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G

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

T91P-6256-A T92P-6256-A

T96T-6256-AR T96T-6256-B

303-465 303-574

303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575

303-380 303-413

303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575

303-380 303-413

303-S568 303-557

No.

Parts List & Operating Instructions

Ford Tool Application Chart

Ford

Year Model Engine Tool Description Part No.

American

Part No.

1998-2008 Ranger 3.0L V6 Cam Sensor Synch Tool 6473 (511540) 303-589

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

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

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) 303-638

1996-1997 Sable 3.0L V6 2V Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529

1998-2005 Sable 3.0L V6 VIN U Cam Sensor Synch Tool 6473 (511540) 303-589

1998-2006 Sable 3.0L V6 VIN Z Cam Sensor Synch Tool 6473 (511540) 303-589

2013-2014 Taurus 2.0L Cam Alignment Tool

Crankshaft TDC Timing Pin

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) 303-589

1998-2006 Taurus 3.0L V6 VIN Z Cam Sensor Synch Tool 6473 (511540) 303-589

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

2010-2013 Transit 2.0L VIN N Cam Alignment Tool

Crankshaft TDC Timing Pin

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) 303-589

1996-1998 Windstar 3.8L V6 Cam Sensor Synch Tool 6469 (511536) T96T-12200-A 303-562

1999-2003 Windstar 3.8L V6 Cam Sensor Synch Tool 6470 (511537) 303-630

2006-2009 Zephyr 2.3L VIN Z Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465

6478 (511546) 6479 (511547) 6480 (511548) 6481 (511549) 6482 (511550) 6484 (511552) 6485 (511553 & 4)

6474 (511541) 6475 (511542)

6009 (511532) 6020 (511555)

6474 (511541) 6475 (511542)

T97T-6256-B T97T-6303-A T97T-6256-D T97T-6256-C T97T-6256-A T97T-6K254-A T97T-6256-F, -G

T94P-6256-CH T97P-6000-A

T91P-6256-A T92P-6256-A

T94P-6256-CH T97P-6000-A

Ford

Global Part

No.

303-564 303-573 303-576 303-577 303-578 303-571 303-565, -575

303-465 303-574

303-380 303-413

303-465 303-574

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)

same as

Ford No. 303-380

(T91P-6256-A)

Note: The 1991 4.6L 2V V8 application does not require the use of tool No. 511555 (6020).

1997 – 2002 5.4L F-Series Truck 1997 – 2005 4.6L Mountaineer (VIN W) 1997 – 2002 4.6L Mustang (VIN W)

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 ats 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.

1997 – 1998 4.6L F-Series Truck

1996 – 2004 4.6L Mustang (VIN X) 2003 – 2004 4.6L Mustang (VIN Y) 1998 – 1999 5.4L Navigator

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

Figure 1

The 1991 4.6L 2V V8 application does not require

the use of tool No. 6020.

No. 511532 (6009)

Ford Camshaft Positioning Tool

No. 511555 (6020)

Ford Camshaft

Positioning Tool

Figure 2

All other applications.

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.

4. Assembly: Install Camshaft Positioning Tool

(511555/6020) and Cam Positioning Tool (511532/6009) into each camshaft end, as shown, before installing timing chains and tensioners to prevent valve train damage.

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

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.

2. Rotate crankshaft so outer vane on crankshaft pulley hub assembly

engages both sides of tool. Tighten

No. 6466

(511533)

sensor assembly retaining bolts to

specications.

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).

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 specications.

Camshaft

Sensor

Housing

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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 t correctly only one way. The side of tool marked UP must be facing the technician and top of engine.

No. 6468 (511535)

3. Follow vehicle service manual

procedure to service timing belt as required. Remove tool when nished.

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511536 (6469) Ford Camshaft Sensor Synchronizer Tool

Application: 1997 3.8L V6 Cougar, Thunderbird

1997 – 2008 4.2L V6 Econoline, F-Series Truck

1996 – 1998 5.0L V8 Ford Explorer, Mercury Mountaineer 2004 – 2007 4.2L Freestar, Monterey 1996 – 1998 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.

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 specications.

No. 511536

(6469)

Camshaft Sensor Housing

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511537 (6470) Ford Camshaft Sensor Synchronizer Tool

Application: 1999 – 2002 5.0L V8 Explorer, Mountaineer

2004 – 2007 3.9L Freestar (VIN 6)

2004 3.9L Monterey (VIN 6)

1999 – 2004 3.8L V6 Mustang 1999 – 2003 3.8L V6 Windstar

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

Camshaft

Sensor

Housing

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. 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

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

according to instructions in the vehicle service manual. Torque fasteners to factory specications.

511538 (6471) Ford Camshaft Sensor Synchronizer Tool

No. 511537

(6470)

Application: 1993 – 1995 3.0L V6 Ford Taurus/Mercury Sable

Note: Same as Ford No. 303-453 (T93P-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 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 specications.

No. 6471

(511538)

Camshaft

Sensor

Housing

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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.

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 specications.

511539

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

No. 511539

(6472)

511540 (6473) Ford Camshaft Sensor Synchronizer Tool

Application: 1998 – 2008 3.0L V6 Ranger

1998 – 2005 3.0L V6 Sable, Taurus (VIN U)

1998 – 2006 3.0L V6 Sable, Taurus (VIN Z)

1998 – 2003 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.

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 specications.

No. 511540

(6473)

Camshaft Sensor Housing

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511541 (6474) Ford Camshaft Alignment Tool

Application: 1994 – 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 2005 – 2008 2.3L Escape, Mariner (VIN Z) 2009 – 2014 2.5L Escape (VIN 7) 2005 – 2008 2.3L Escape Hybrid, Mariner Hybrid (VIN H) 2009 – 2012 2.5L Escape Hybrid, Mariner Hybrid (VIN 3) 2012 – 2014 2.0L Focus (VIN 2) 2000 – 2004 2.0L Focus (VIN 3) 2002 – 2004 2.0L Focus (VIN 5) 2005 – 2012 2.0L Focus (VIN N) 2003 – 2007 2.3L Focus (VIN Z) 2006 – 2009 2.3L Fusion, Milan, MKZ, Zephyr (VIN Z) 2010 – 2014 2.5L Fusion (VIN A) 2010 – 2014 2.5L Fusion Hybrid (VIN 3) 2009 – 2012 2.5L Mariner (VIN 7) 2010 – 2011 2.5L Milan 2010 – 2012 2.5L Milan Hybrid, MKZ Hybrid (VIN 3)

2014 2.0L MKT

2012 2.0L MKX (VIN 9) 2010 – 2012 2.5L MKZ (VIN A) 2001 – 2011 2.3L Ranger (VIN D) 2010 – 2013 2.0L Transit (VIN N)

Note:

Same as Ford No. 303-465 (T94P-6256-CH).

•

The camshaft timing slots are offset. If the

CAUTION: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent rotation can result in engine damage.

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 specications.

5. Remove the tool.

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

•

camshaft alignment timing tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

No. 511541

(6474)

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 specications.

No. 6475

(511542)

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511543 / 511544 (6476) Ford Camshaft Positioning Tool Set

Application: 1997 – 2002 4.6L Econoline, F-Series Truck (VIN W)

1997 – 2002 5.4L Econoline, Expedition, F-Series Truck 1997 – 2002 6.8L V10 Econoline 1998 – 2002 5.4L Navigator

Note:

511543 511544

• 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 specications.

2-Hole Camshaft Sprocket

18 mm Hex Hd. Camshaft Sprocket

No. 511543

No. 511544

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511545 (6477) Ford Camshaft Holding Tool

Application: 1997 – 2009 4.6L Econoline, F-Series Truck (VIN W)

1997 – 2002 5.4L Econoline (V8), Expedition, F-Series Truck

1997 – 2002 6.8L V10 Econoline 1998 – 2002 5.4L V8 Navigator

No. 6477

(511545)

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.

No. 511543

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.

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)

Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E)

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 specications.

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511547 (6479) Ford Crankshaft Holding Tool

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 specications.

No. 511547

(6479)

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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:

• Same as Ford No. 303-576 (T97T-6256-D).

• This tool is used with No. 511549 (6481) Ford Camshaft Holding Tool.

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 specications.

No. 511549

(6481)

No. 511548

(6480)

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.

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 specications.

No. 511549

(6481)

No. 511548

(6480)

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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.

No. 511546

(6478)

No. 511550

(6482)

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 according to factory specications.

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.

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 specications.

No. 511551

(6483)

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

Camshaft Sensor Housing

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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 specications.

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

511553 / 511554 (6485) Ford Camshaft

Gear Bolt Socket Extension

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)

2003 – 2011 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. 511552

(6484)

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 specications.

WARNING: Wear eye protection that meets ANSI Z87.1 and OSHA standards.

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