Camshaft Synchronizer bushing?

MJK27435

MEMBER
2000 FORD WINDSTAR
3.8L
V6
2WD
AUTOMATIC
220,000 MILES

I like several other folks in here have experienced a failure of the drive gear and the driven gear on the camshaft synchronizer. My cam gear is severely cupped (worn) right down the middle, in respect to front and back of the gear. The synchronizer gear is more worn on the top, closest to the electrical side. I am wondering if the brass bushing in the timing cover, that the synchronizer gear rests on while it is installed has worn to the point of allowing a misalignment. When measuring it with a caliper, I get a thickness of ~ 2.95mm or 0.1140 inches. I am wondering if this should be a little thicker, maybe closer to 3mm or 0.1180 inches. Is this bushing replaceable and if so, where can you buy it, I have searched pretty well, but nothing comes up. Thanks

3 Replies

KEN L

MASTER CERTIFIED MECHANIC
47,526 POSTS

I have never heard of a brass bushing inside the block for the distributor or synchronizer. Can you take a picture and upload it? Maybe someone repaired the block in the past? Here is all they show when it comes to the camshaft synchronizer. Check out the images (below). Let us know what happens and please upload pictures or videos of the problem.

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Thursday, October 13th, 2022 AT 12:00 PM

MJK27435

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My apologies, the brass bushing is in the timing cover, the synchronizer gear rides upon the top of it, the shaft goes through it. I have it placed in the photo where it goes in the timing cover, just not pressed in. My question is, what thickness should that shoulder on the bushing be? That flange is 2.95mm (0.1140 inches) ish thick. Not knowing what the tolerances are, I was wondering if it had worn to where the gears are not meshing together correctly and causing what you see in the photo to the cam (drive) gear. The middle oof the gear is cupped out, and the wear on the synchronizer is worn on the top section, more so than evenly. The synchronizer has been in just over a year, the prior one appears to have worn perfectly, in the middle of the synchronizer gear. Thanks for getting back to me. Michael

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Thursday, October 13th, 2022 AT 3:04 PM

KEN L

MASTER CERTIFIED MECHANIC
47,526 POSTS

Thanks for the images. Yep, that is worn. You should have about.002 to.004 clearance in the bushing to synchronizer shaft. Also please try to turn the oil pump because this kind of wear can indicate an oil pump that is going out FYI.

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Saturday, October 15th, 2022 AT 11:38 AM