I have a 97 Mustang 3.8 with a leaking timing chain cover gasket. We're replacing it without pulling the engine, so we've done all of the tedious removals. Now that we've gotten to the actual cover, we can't seem to get the dang thing off! We're about 99% sure that we've gotten all of the bolts out including the easy-to-miss allen bolt, but it is stuck good! How can we get this thing off without ruining the cover and having to buy a new one? We're at the point that if we can figure it out, we're going to break the dang thing off!
Any tips/advice would help.
If all the bolts are out-check the oil pan could be holding it in place
NOTE: Oil pump is attached to front cover and is driven by camshaft position sensor.
Disconnect negative battery cable. Drain cooling system. Remove air cleaner assembly and air intake duct. Remove electric cooling fan and fan shroud. Remove drive belt(s) and water pump pulley.
Remove power steering pump, with hoses attached, and mounting bracket bolts and secure them aside. Remove A/C compressor front support bracket, leaving compressor in place (if equipped). Disconnect coolant hoses at water pump. Disconnect upper radiator hose at thermostat housing.
Position piston No. 1 at TDC of compression stroke. Note position of camshaft position sensor electrical connector. Disconnect wiring harness connect from camshaft position sensor. Remove camshaft position sensor and CMP synchronizer assembly. See Fig. 6. Raise and support vehicle.