I hope you've gotten an answer by now - 2 months later. Anyway, my 97 Taurus with 3.0L single cam, sheared the syncronizer pin that drives the sensor and oil pump. Replacing the sensor was part of the process.
First, locate the timing mark just behind the crank pulley. It's a pointed piece protruding from the block just car-forward of the crank sensor which sits above the crank pulley. If practical, loosen the spark plugs so the engine can be positioned easier with a socket and flex handle. You must put the TDC mark on the crank on the timing mark at the top of the compression stroke. To do this, bump the starter while holding your finger over the #1 plug hole to feel compression, OR insert a piece of rubber hose in the plug hole with a balloon on the other end and watch for it to inflate. This will be the beginning of the compression stroke. Stop when TDC mark is just short of timing mark.
Put a 21mm socket and flex handle on the crank nut to position TDC mark on the timing mark. DO NOT CRANK OR BUMP STARTER or you start over. Disconnect the negative terminal from battery. Remove the sensor connectors on the throttle and intake tubes. Undo the air intake hose, PCV, and throttle assembly (leave throttle and cruise cables attached - it will swing out of the way nicely) Next, remove the wire protector just above the cam sensor and tie them back out of the way. Before you remove the sensor, you must have a sensor positioning tool (an over priced $50 plastic part available on internet or at some parts stores) which aligns the syncro and sensor to the camshaft.
Make a mark on the sensor housing and intake manifold so that you can align it after replacing the sensor. Remove the sensor connector, and the 2 sensor bolts with a 5.5mm socket and lift it straight up. You will probably find the small magnet that fell out of the sensor. Unless the syncro needs replacing, leave it as is. Using the alingment tool, rotate the housing and the sensor vane until the tool fits flat on top of the housing, and point the arrow toward the housing washer and clamp nut. Attach a new sensor - hopefully with one whose magnet is completely enclosed. Re-assemble in reverse order. Check timing with a timing light, referring to shop manual for correct setting.
Shop manual says that whenever the battery is disconnected, the car may have to be driven as much as 10 miles for the computer to learn it's timing strategy again.
Sunday, August 12th, 2007 AT 5:17 PM