I just purchased a non-running 1991 F250 with a 4.9L I6. When I turn the crankshaft the distributor does not turn. First thing I did was check the distributor, which is fine. I then pulled the front timing cover off, preparing to change the timing gear. Both the gears are fine and turn correctly. I then popped the intake and valve cover off. When turning the crank, nothing up top moves. I pulled the inspection plate off the side and the lifters are not moving. SO, I am assuming the camshaft is broken. How hard is it to pull the camshaft out of the bore? Do I have to drop the oil pan to get to the camshaft? How often do these thing break the camshafts? What would cause it to break? Right now, I am looking at pulling the cam and lifters, replacing the timing gears, oil pump and cam and lifters - and gaskets for everything! Any other things I should keep my eyes open for? Thanks for the help.

 

Are you sure the front of the camshaft is turning with the crankshaft? That is the first thing I would make sure of. I have never seen a broken camshaft and I have been around a long time and a whole lot of engines.

 

I have the front cover off and the gears are in great shape. They turn in sequence together. I have not tired unbolting the cam to see if the front just drops off.

 

Then the camshaft must be broke if the cam gear is properly bolted to the cam. You don't have to remove the oil pan to replace the cam. You may have to pry through the lifter holes to get the cam started out.

 

That is what I thought. I was hoping that the cam would come out easy, from the top and without scratching the bearings. I am also going to check to make sure the cam is turning with the cam gear. I could always get lucky and just the key split and the gear is turning freely on the shaft. I have seen that a couple of times, just with other types of vehicles.

 

Well, after messaging you, I went back out to check the front gear set again. The fabric gear on the camshaft has come disconnected from the metal hub section and the camshaft. It is just spinning freely on the shaft now! Which is going to make taking it off REALLY fun. Any suggestions for removal would be appreciated.

 

If the metal hub on the cam gear is still connected to the cam, what I think you mean, normal disassembly should work. Depending on the bevel of the gears, does the crankshaft gear slide away from the cam gear first? Kind of hard to say without looking at it.

 

I looked in my Haynes manual and it looks like you may need a puller that has 2 bolts that screw into the cam gear and another bolt that screws into the center of the cam. I never worked on a Ford 6 cylinder before. It looks like you need a similar puller to pull the crankshaft timing gear. You will want to replace them as a set.

 

Update - the fiber section broke off during removal. I have tried everything I know on removing the steel sleeve that attached the fiber gear to the camshaft. Any great ideas for removal? Got rid of my dremel tool several years ago, which I have heard is an option. The other option is pulling the camshaft and cutting the dang thing off. Any help someone can give me would be appreciated.

 

I would guess you need the proper puller. Without seeing the gear, I could only guess. The Haynes manual shows bolt holes in the cam gear. The replacement cam gears on Rockauto show 4 holes in the gear. Maybe take a picture of your cam gear and take it to your favorite parts place and ask if they have the proper puller.

 

If you have access to a press its much easier just to pull the cam to remove gear. Also for assembly put the cam in a deep freeze for a few hours and the new gear in oven at 300*. It will drop on with no need for press

 

I recall having to cut the hub off of an i6 once upon a time.

 

Is there enough metal to drill and tap two holes and use a standard puller? Doesn't need to be real precision, just about 180° apart, reasonably straight in. right angle drill may be needed to clear the radiator, or remove radiator. Seems easier than removing cam. The type of puller I'm thinking of is used (I believe) to pull steering wheels.