We finally got the VCT cam gear off of the Zetec engine last night. It took 3 of us, and 2 wrenches. There are a few write-ups on how to remove swap the gears around, but no one indicated that it would be this difficult to turn the bolt.
As I said, it takes two wrenches. A 16mm wrench fits on the inverse Torx bolt that is inside the VCT gear (under the cover), even though you should probably have the correct wrench. Also, you will need another wrench to hold the cam in place. With a little force, we were able to force a 15/16" wrench over the hex on the cam.
This could have been because we rounded it a little by using an adjustable wrench, or because of the casting being a little rougher than it could have been. Regardless of the case, it made it difficult to fit the wrench on there. A small hammer made it easier....
Also, I did it without any instruction as to how to install the VCT Delete Kit. I really hope I got the O-ring in the correct location.
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