Not sure if this has been covered already, but I couldn't find it with a simple search.

I bought underdrive pulleys from Mike Troyer's site about a month or so ago, but when I tried to install them I couldn't get the crankshaft pulley/harmonic balancer nut to budge. Two shops I went to both wanted over $200 to install them, so I said, "No way," and just waited 'til I could get to my stepfather's house (he has nice air tools).

Well, that day was yesterday. But when I tried to install the kit I ran into two problems which I was hoping you fine gentlemen would know how to remedy.

First, after I got the harmonic balancer retainer bolt out, I tried pulling the harmonic balancer with a regular harmonic balancer puller kit. After a good while of ratcheting away with two torque bars I noticed that the center portion of the puller was actually starting to warp. So I backed it off and put the bolt back in. Is there some special Ford tool I have to use for this, or did I just miss something?

Second, I noticed that the water pump pulley in the kit is large enough that the unused accessory mount(?) nearby will interfere with the serpentine belt. Does anyone have any suggestions on what to do about this (grind it down, cut it off, etc)?

I'm going to feel like an idiot if these are overly simple problems, but at least then I can get the kit on. I wish I could call Troyer while I'm working on the truck, but I never seem to have a chance to install these mods during his business hours. Maybe Mike'll see this post and be able to reply. To anyone who can reply, thanks in advance for your help.

 

Hi.

A simple puller is all that's required to get the balancer off. Make sure the end that seats on the shaft isn't binding against the balancer itself ( end too large ).

The instructions clearly state that on 5.4's, you need to do a little grinding to obtain proper clearance.

Finally, the factory bolt is torque-to-yield. If you reinstalled it, you can't retorque it again.

And ensure you follow the tightening sequence as indicated in the instructions ( or on this forum) *exactly* for the new bolt.

Take your time, it's doable. Hey - if a spaz like me can do it ...;-))

Cheers

 

This is what I was worried about. There was something in the center of the balancer that seemed like it wasn't in as good as the balancer itself, but it didn't want to come out and when I pulled on it it leaked some kind of fluid. Does this need to come out first?

And yeah, I saw in the instructions where it said most 5.4s require grinding, but I wasn't sure if maybe some people found it easier just to cut the whole thing off, or maybe even tell me what you used to grind it (die grinder would be most obvious choice, but I don't have one so I was wondering if anyone had any other ideas).

Also, I used the new bolt I'd bought for the aftermarket balancer when reinstalling. Wasted $6 'cause now I have to get another, but it's better than not having a truck to drive.

Anyway, thanks for the reply and the hints.

Jeff

 

To be honest, on my 4.6, I gave up getting the fan off (got a 3 pulley setup from MAC) and ran short on patience and pneumatic chisel to loosen the fan. I found a guy that owns a garage; charged me $60 for the 20 minute job.

Find a small-time mechanic, offer in that price range to get 'er done.

Curt

 

ucf - When you removed the bolt for the balancer did the nut also come out? I did this mod several years ago and had a simialr problem. I removed the bolt, put the puller on and cranked away and nothing happened. What I discovered was that the RTV sealant placed in the keyway oozed out and was on the backside of the washer. It held the washer on and it did not come off with the bolt. You can't see this unless you use a small mirror and light. Once I realized what happened and I removed the washer, the balancer popped off in a couple turns.

 

So there's a washer there? That would explain it, for sure. The only thing I got out was the bolt itself - it dropped right out, but nothing else. If I try again, I'll certainly make sure to get the washer out, too.

Many thanks for the informative response. Also, did you have to grind down the accessory mount? If so, how hard is the metal? Will a cut-off wheel suffice? Thanks again.

Jeff

 

The washer got me yesterday. I found this post, went out, removed the washer and had the pulley off in two minutes ! The puller was pushing against the washer which held the pulley on. A lose, lose situation.

I will also mention to pay attention to the puller bolt (the big screw in the middle ). Mine went into the threaded hole (where the pulley bolt goes) and buggered up the threads. I ended up using a washer on top of a socket for the puller bolt to push against to keep it from going inside the crankshaft and causing further damage.

My heart was going pitty-pat, and my stomach was up in my throat when I got the new pulley on, and started to re-install the bolt. It seems to have worked out OK, but take care of those threads inside the crankshaft !

Edited to add -

The material that you need to grind away is aluminum, and is pretty soft. I used a dremel with a little round sanding drum. The ones with the rubber inside so that you can change them out as they wear. At some point it was going too slow, so I put a sanding disk in my drill and went to town. The sanding disk worked great !

I had plenty of room in there, as I was also installing electric fans, so take a look and see if you can fit a drill with a sanding disk. Kind of hold the new pulley up and see what you have to remove, it isn't that bad at all.

-John

 

Thanks for the reply. Awesome info, exactly what I was looking for.

Jeff