2004 F-150 Underdrive Pully Install
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From: Yucaipa, California
2004 F-150 Underdrive Pully Install
I got an e-mail asking me about my underdrive pullys. I thought all of you might like to hear of my experence and a little how to and what I encountered. So here goes.
The set is comprised of two pullys. One is for the water pump and is quite a bit larger than original. The second is the main crank pully or Harmonic balancer pully. Yes it is balanced. It is smaller than the original.
On the 2004 F-150 to change the pullys first you have to remove the air intake tube off the throttle body. Then remove the top water hose and tie back out of the way. (this means draining a bit of coolant). Next is removing the fan from the water pump and letting it remain inside the fan shroud. This requires that you unscrew the fan shaft from the front of the water pump. It has a large nut on the shaft and unscrews counter cloclwise facing the engine compartment from the front of the vehicle. Now then remove the fan shroud along with the fan. You now have the front of the engine exposed. Use a 1/2 breaker bar into the 1/2 inch square hole in the idler pully to remove tension from the belt and remove the belt. Only 4 bolts hold on the water pump pully, easy to remove.
Now its time to really get to work on removing the original harmonic crankshaft pully. A pully puller is a MUST here. A three legged puller won't work. You need a puller that attaches to the inside bolt holes in the pully. You also need a means of holding the crankshaft from turning. I had the puller but had to make up a home made strap wrench to go around the original pully to hold it from turning. You can use the original belt for the strap wrench material. I also had to add a three foot pipe over my breaker bar to get enough leverage to break the crankshaft bolt tension. I tried my old impact wrench but it would not budge. Yours may do the job. Go figure.
After removing the pully clean off the crank shaft with a rag. Put high temp silicon gasket ATV on the keyway inside the new pully before mounting it. This insures no oil leaks at the keyway. My puller also allows me to install a pully but the pully kit from Troyer also includes a long bolt to be used to get the pully started. Then used a NEW crankshaft bolt to finish the pully install. Don't run the long bolt in all the way as it will bottom out and maybe ruin your threads. All this is on the direction sheet with the pullys.
The water pump pully just bolts on but beware! its skirt WILL hit an unused mounting ear on the front cover. You will have to grind it down until the pully skirt is clear. Not really hard to do especially if you have a dremel too or small power grinder. Do this last after you get the crank pully on because there is a lot of metal filings you don't want to get into your crankshaft seal. Spin the water pump pully to check clearence.
Now with both new pullys installed just reverse the disassembly to finish up Replace your orignal belt with a GatorBack belt. You can get them at most suppliers or order one from Troyer when you order the pully set. If your not handy with all this then maybe its worth the dime to get your local mechanic to do the work. But keep an eye on whoever does this to make sure they follow directions.
Hope this gives you an overview of level of difficulty that this requires. Really not much but it took me about half the day to get it done, no rushing!
Happy New Year to all
Larry
The set is comprised of two pullys. One is for the water pump and is quite a bit larger than original. The second is the main crank pully or Harmonic balancer pully. Yes it is balanced. It is smaller than the original.
On the 2004 F-150 to change the pullys first you have to remove the air intake tube off the throttle body. Then remove the top water hose and tie back out of the way. (this means draining a bit of coolant). Next is removing the fan from the water pump and letting it remain inside the fan shroud. This requires that you unscrew the fan shaft from the front of the water pump. It has a large nut on the shaft and unscrews counter cloclwise facing the engine compartment from the front of the vehicle. Now then remove the fan shroud along with the fan. You now have the front of the engine exposed. Use a 1/2 breaker bar into the 1/2 inch square hole in the idler pully to remove tension from the belt and remove the belt. Only 4 bolts hold on the water pump pully, easy to remove.
Now its time to really get to work on removing the original harmonic crankshaft pully. A pully puller is a MUST here. A three legged puller won't work. You need a puller that attaches to the inside bolt holes in the pully. You also need a means of holding the crankshaft from turning. I had the puller but had to make up a home made strap wrench to go around the original pully to hold it from turning. You can use the original belt for the strap wrench material. I also had to add a three foot pipe over my breaker bar to get enough leverage to break the crankshaft bolt tension. I tried my old impact wrench but it would not budge. Yours may do the job. Go figure.
After removing the pully clean off the crank shaft with a rag. Put high temp silicon gasket ATV on the keyway inside the new pully before mounting it. This insures no oil leaks at the keyway. My puller also allows me to install a pully but the pully kit from Troyer also includes a long bolt to be used to get the pully started. Then used a NEW crankshaft bolt to finish the pully install. Don't run the long bolt in all the way as it will bottom out and maybe ruin your threads. All this is on the direction sheet with the pullys.
The water pump pully just bolts on but beware! its skirt WILL hit an unused mounting ear on the front cover. You will have to grind it down until the pully skirt is clear. Not really hard to do especially if you have a dremel too or small power grinder. Do this last after you get the crank pully on because there is a lot of metal filings you don't want to get into your crankshaft seal. Spin the water pump pully to check clearence.
Now with both new pullys installed just reverse the disassembly to finish up Replace your orignal belt with a GatorBack belt. You can get them at most suppliers or order one from Troyer when you order the pully set. If your not handy with all this then maybe its worth the dime to get your local mechanic to do the work. But keep an eye on whoever does this to make sure they follow directions.
Hope this gives you an overview of level of difficulty that this requires. Really not much but it took me about half the day to get it done, no rushing!
Happy New Year to all
Larry
