Synchronizer Sqeak Video

[scca28]

Just thought I'd share this after I wasted time and money replacing pulleys and a belt trying to track down the annoying squeak on our '02 Windstar. The squeak became more frequent and eventually we had a few stalls before I researched it further and found out about the synchronizer being a possible culprit. Here's the proof:
http://www.facebook.com/v/1544716510510
And, there were a few metal flakes stuck to the magnetic part of the sensor...
Hope this helps!

[Redline69]

It could be worse. I replaced my waterpump thinking THAT's where the squeak was coming from. Now that was not fun..lol.

AND I replaced my fixed idler..

Then I came here,and was informed of the synchronizer squeak,in the area behind the waterpump.

When I got my synchronizer out,it was VERY tight. I could barely turn it by hand. I imagine it would have failed soon enough.

[scca28]

Originally Posted by Redline69

It could be worse. I replaced my waterpump thinking THAT's where the squeak was coming from. Now that was not fun..lol.

Yeh man, at least I was lucky I read about it here as well before I attacked the water pump!
I found the hardest part of the job was pulling the pipe out of the water pump to make room for the synchro to come out.
The new one came with the alignment tool, but I used the eyeball method. Before I removed it, I marked up the old one in relation to the engine and also the position of the rotor to the body of the synchro. I made the same marks on the new one and on the second try it went right into place with the same alignment as the old one!
Soon as we started the engne I could feel a difference in the way it was running, real smooth and more power pulling out from a stop. I guess the metal flakes on the old sensor were messing with the timing signal? The bearing must be beat, there's a lot of side to side play in the shaft.
Anyway, just wanted to post the video so someone else might be able to identify their squeak before they go out and spend a lot trying to track it down...