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Discussion Starter #1
Hello Hello,
I have been working with a friend of mine to solve a no start condition on his 96 stang 3.8L that suddenly shut off while driving. Using a PC based Scan tool as well as multiple OTC scan tools (verified on multiple other cars< BMW, VW, HONDA, SUBI, other FORDs, and Chevy), the stang shows no codes, no "Theft" light, inertia switch isn't tripped, Full battery at 12.6v, and after using a spark tester it shows no spark.
We replaced the PCM, the Ignition coil pack, Checked all fuses only the radio fuse was blown but was know about, and crank position sensor. We thought for sure the crank position sensor was at fault as it had been worn into a "D" shape from the harmonic balancer being in contact with it. once we began checking the sensor we read a voltage change from only .1 v up to .438 volts AC and yes the DVOM is set to the right range.... As it never reach 1 v we thought we had it. We cant seem to install the new Crank position sensor in the correct orientation due to it contacting the harmonic balancer. For giggles we decided to give it a try anyways and still no spark.

Im by no means a Beginner in the automotive world but were lost on this one.

The only thing we havent checked for is opens between the sensors and the PCM. since we have no Codes even after trying to make it CEL by disconnecting the Idle Air Control Valve and the MAF then attempting to start again. Grounds have also been redone to ensure they are good....The only item we haven't touched is the cam position sensor. Is there something were missing? Anyone ever even had this problem?
 

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Discussion Starter #3
@g96v6-250k
Yup 12v is reaching coil. Just checked for opens or shorts to all wires too and from PCM. found nothing wrong. My idea is that the harmonic balancer is supposed to have a spacer between it and the block that was placed between the balancer and the pully instead since its .10 to close to the block for the crank postition sensor to be installed properly and has worn down the old sensor that amount. Not sure if Stangs have this spacer or not, how ever im gonna find out tomorrow after I buzz the bolt out using a Impact. Im pretty confident we found the problem since the Crank position valve is showing open when probed on the sensor side. To my knowledge the should be resistance till a magnet or metal breaks the magnetic field of the sensor.

So if anyone can confirm whether there is indeed in fact a spacer that is between the Harmonic balancer and the case it would be appreciated since i highly doubt the crank has walked towards the transmission.
 

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the only thing I can guess is the balancer weight has moved on the rubber. does the balancer look brand new or was it recently replaced? got any pictures? CKP sensor should be around 600-700 ohms. air charge temp sensors will also cause no start, but im not sure if it cuts fuel or spark when it goes bad.
 
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