Timing chain cover gasket on a 96 Ford Wind star?

Answer 1

Answer to replace timing cover gasketIt's a big job, shops charge well over a thousand dollars to do it. The original gaskets were poor, and fail a lot. Ford has a much improved replacement, it costs about 15 bucks!The crankshaft pulley and harmonic balancer must come off, then you have to remove the front section of the exhaust system and the oil pan. From above, remove the alternator, Power Steering pump and water pump. On the 3.8 engine you have to remove the camshaft position sensor, but mark the position of the sensor body, and also the vane inside - if you put it back wrong the engine will run, but badly. Then you have to jack up the passenger side of the engine in order to remove the timing cover. You have to undo all the bolts and studs and lift them out with the cover, mark the position of the bolts and studs because they are all different lengths. Do NOT miss the small machine screw with the Allen head just below the oil pump, it will probably be hidden behind a gob of greasy dirt - if you try to remove the cover with this screw still in place you will crack the cover! A new one is about $150 on line!

Carefully remove all the old gasket material, fit the new gasket, and reverse the above. Good luck!

Edit: Hi, I'm just gonna touch on a few notes here. First off, this is not a job for a "think i can do it" do it yoursefler. It requires a few special tools. 1: power steering pulley press tools. it is a press on pulley. 2: crank shaft pulley press tool, 3: (optional) stud extractor set with 1/4 stud extractor, this makes getting the timing chain cover off with very little to no lifting of the engine (note: you will need to remove nut from front pass motor mount to frame and lift motor up to remove water pump, IT WILL NOT CLEAR UNLESS IT IS LIFTED 3") Normal tools are as follows. 1: 1/2" drive socket set range from 13mm-21mm, 3", 6", 12", 1/2" drive extensions, some of which you may not use. 1/4" drive socket set range from 4.5mm-13mm, one 3" extension. set of 6 point box end wrenches range from 8mm-15mm, pair of pliers, dead blow or normal hammer, rubber mallet, few pry bars, penetrating oil, and alot of patience...

Also Note: water pump may hang/ stick to timing cover studs. DO NOT PRY HARD. pay attention and see if pump tries to slide off the studs. you will clearly see the stud that are making it stay on. at this point is were you would use the stud extractor set. be very careful not to break the stud off in the engine block. this will also free the pump from stud and remove pump. same note with timing chain cover. if stud making cover stick find the troublesome stud and remove it. i would remove all studs if the first two came out easily. i know the studs will not come completely out so just let them chill in the timing cover for now till its time to remove it. if i have left anything out please feel free to update further.