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apparently the timing gear on the crank shaft is not keyed…and can sometimes slip..resulting in gear marks that still line up..but the shaft is out of position.
Yep, the fix is to TIG weld the sprocket to the crank. Surprised Ford uses a press fit sprocket, guess they think there will never be enough resistance on the cam to cause it to slip out of time, unless the CP4 locks.
It's called an interference fit. It's quite common. I had the crank gear and the cam gear TIG welded on my 97 7.3. The
interference fit was reliable with an OEM pump, but not with higher volume pumps. I had a T500 on mine. I miss that truck..