I have been using a 4.0L Jeep Cam Position Sensor and it has been working well.
I just wanted a shorter version.
Then I ran across this post and it lead me to this project. Custom Cam Position Sensors - General Inquiry and Discussion, Feedback Appreciated
I already had a spare 4.0L Jeep sensor.
So I ordered a '99-04 Ford Mustang V6 Cam Synchronizer for about $20 from Ebag.
I had already made an adapter for the Jeep sensor from an old big block distributor by chucking it up in my old metal lathe and cutting the base off and turning the center hole for a snug fit on the sensor. So, I used it. Just had to turn the sensor hole a little larger.
The Ford sensor arrived yesterday. It had a sticker on the cap to body that said "Warranty Void If Removed". First thing I did was removed the cap along with the sticker.
Then proceeded to disassemble the rest of the sensor down to the main body.
The "Shutter" on this sensor is very narrow compared to the Jeep one. I know the Jeep shutter works so that is the shaft I am using.
Since the body of the Ford sensor is way shorter than the Jeep sensor, the shutter shaft had to be shortened. So I did a trial assembly of the shaft to the Ford body and determined the length and cut it down.
Once cut to length, I had another problem. No Tang to engage in the intermediate shaft of the engine.
When I was given my metal lathe by a good friend a few years ago, it came with a number of attachments. One of those being a milling attachment. I have now taught myself how to use it and was able to mill the tang back onto the shaft.
To secure the sensor body to the distributor adapter, I drilled and tapped two 4 x 40 holes through the body and adapter and used two 4 x 40 x 3/4" Button head Stainless Steel machine screws.
Here is the completed "Home-Brewed" Cam Position Sensor..
I just wanted a shorter version.
Then I ran across this post and it lead me to this project. Custom Cam Position Sensors - General Inquiry and Discussion, Feedback Appreciated
I already had a spare 4.0L Jeep sensor.
So I ordered a '99-04 Ford Mustang V6 Cam Synchronizer for about $20 from Ebag.
I had already made an adapter for the Jeep sensor from an old big block distributor by chucking it up in my old metal lathe and cutting the base off and turning the center hole for a snug fit on the sensor. So, I used it. Just had to turn the sensor hole a little larger.
The Ford sensor arrived yesterday. It had a sticker on the cap to body that said "Warranty Void If Removed". First thing I did was removed the cap along with the sticker.
Then proceeded to disassemble the rest of the sensor down to the main body.
The "Shutter" on this sensor is very narrow compared to the Jeep one. I know the Jeep shutter works so that is the shaft I am using.
Since the body of the Ford sensor is way shorter than the Jeep sensor, the shutter shaft had to be shortened. So I did a trial assembly of the shaft to the Ford body and determined the length and cut it down.
Once cut to length, I had another problem. No Tang to engage in the intermediate shaft of the engine.
When I was given my metal lathe by a good friend a few years ago, it came with a number of attachments. One of those being a milling attachment. I have now taught myself how to use it and was able to mill the tang back onto the shaft.
To secure the sensor body to the distributor adapter, I drilled and tapped two 4 x 40 holes through the body and adapter and used two 4 x 40 x 3/4" Button head Stainless Steel machine screws.
Here is the completed "Home-Brewed" Cam Position Sensor..
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