Physically damaged Cam Pos Sensor

[silentdub]

Hey guys, We have a 2005 Ford Expedition, 5.4L and there was a code for the CAM POS Sesnor, bank 2. When I removed the old sensor it was clearly damaged, the plastic was broken and worn away. We replaced the cam sensor and within a few days, the same code came back, we pulled the sensor and again, the brand new sensor is damaged the same way.

The only two things I can see it hitting is the timing plate or the chain itself. There are no other noises or concerns at this point, just broken sensors.

Is this a sign that the chains/tensioner/guides need to be replaced?

 

[Hamfisted]

Are you getting any "rattling" from the timing chains on cold starts ? Do you have a bore scope tool you can look in the hole and see what it's hitting ? Should be marks on the chain if that's the cause. How many miles on the Expy? Have the chain sets ever been changed before ?

 

[Trainmaster]

I know some aftermarket sensors for BMW's are too long and break off just like that. Maybe wishful thinking that you have cheap knock-off sensors. I'd get one more Motorcraft sensor just to be sure, or at least compare yours with a real one to make sure the sensor depth isn't your problem.

If that's not it, you're going in... And it's getting cold in Phily.

 

[silentdub]

Are you getting any "rattling" from the timing chains on cold starts ? Do you have a bore scope tool you can look in the hole and see what it's hitting ? Should be marks on the chain if that's the cause. How many miles on the Expy? Have the chain sets ever been changed before ?

I didn't hear noise or rattles. We have a scope and plan to do that next. I doubt the chains were ever done, i know they're common for failure. There's nothing else that it can hit, I though the cam sensor picks up off the cam gear which makes the chain that much further away. Strange.

 

[silentdub]

I know some aftermarket sensors for BMW's are too long and break off just like that. Maybe wishful thinking that you have cheap knock-off sensors. I'd get one more Motorcraft sensor just to be sure, or at least compare yours with a real one to make sure the sensor depth isn't your problem.

If that's not it, you're going in... And it's getting cold in Phily.

The one we replaced was damaged too, had some cracks in the plastic. I have a feeling it was replaced previously but no telling. I'll check the length though, still going to spin the motor and scope it. We have a good scope and nice screen so we should be able to see something.