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Thread: Pulley replacement issue

  1. #1

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    Pulley replacement issue

    Hey All,

    Driving an 86 2.3l diesel ranger, 4d55.

    My tensioner pulleys bearing on the lower belt is getting worn and squeaky, so I purchased a new idler from lordco. Thought it was gonna be easy as a bolt in the center. Upon removing the tensioner bracket with the pulley on it, I can't see a way to just switch out the pulley onto the bracket. Would this mean I need the whole bracket with a new pulley on it?

    Thanks!
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  2. #2

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    It looks pretty fixed to that bracket. Clean it up though and take another picture. Sometimes it takes special tools like when removing alternator pulleys. http://www.ebay.com/bhp/alternator-pulley-tool
    Although in this case it doesn't really look that optimistic. Maybe someone else has dealt with this. My truck doesn't have the tensioner pulley.

  3. #3

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    thanks
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  4. #4

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    Ah Nuts. Brought er down to the shop and they said no way to replace the pulley itself, gotta be on the bracket...Called Lordco, they didn't find anything in their computer, rockauto - nada. might be on the hunt for a used one which will be a task...

  5. #5

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    Interesting,
    Just saw you over at the ranger forum (same user title ).
    I had some time today & went looking out of curiosity & the need to educate Myself
    as I no squat about this platform !
    There are complete kits available--- both belts & tensioners--- however the listed apps
    have a generic tensioner(s) pic which looks nothing like Your posted pic... 'one size fits all',

    I thought there were some 4D5x Guru's here that could hook You up ??
    maybe an NOS part as compared to a 'good used' bit.
    There ARE options that could be fabed up, before all that however,
    Hopefully one of said guru's will get involved.

  6. #6

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    Looks to me like the pulley is fastened with a rivet. You can drill out or grind off the small end, install the new pulley and then maybe put a few tack welds back on it. If you don't weld or cant get anyone to weld it then get a bolt for it. Basically you have the bracket .....just have to figure out how to attach the new pulley.
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  7. #7

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    I agree with crvtec90 if the bearing bores are the same. If they aren't I would find a shoulder bolt that fits tightly into the new bearing, it should be a light press fit. If the hole in the bracket is smaller than the threaded portion of the shoulder bolt, I would drill it to size and just bolt to the bracket. If the hole is bigger, I'd weld a washer to the bracket and bolt to it.

  8. #8



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    Just do as Andy 2 said, easiest and quickest way IMO
    Josh
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  9. #9

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    This might help .looks as if you have to remove the pulley as stated above.
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  10. #10

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    It sucks that they didn't design a pulley bracket with a threaded insert. It would almost be just as much work to make a new mounting bracket out of plate steel so there wouldn't be any need to weld up the hole to get the pulley bolt to sit square in position again.

  11. #11

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    I don't know if it's necessary to use a plasma cutter to remove that. That's going to open the hole up too much. You could use a grinder and slowly remove the flange from the pulley side. This will allow the removal of the pulley and leave the stub of the mount sticking out of the bracket. You can then cut the stub off and grind it smooth. If the stub is induction welded to the bracket, you can just drill through with the size you need.

  12. #12



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    Def no need IMO to do as he did with a plasma cutter, it could easily be drilled or grinded off from what I see of the pic.
    Josh
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  13. #13


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    I ran into this once. what I did was drilled the back side of the "Bolt" until the head was removed then pulled the pulley off with the shaft. Then I found a bolt that was the right size and bolted the pulley back on. After that I did 3 tack welds on the bolt head on the back side so it wouldn't turn.

  14. #14

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    I guess now would be a good time to ask if there is room behind the bracket for a bolt head or a stover nut after the bracket is mounted to the block.

  15. #15

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    Some good advice here, cheers.

    Whatup Claych!
    Yeah there would deffinately be room for a bolt head behind the bracket. Thinkin what crvtech90 said sounds like the easiest thing to do. Just need to find someone who could weld it, got a buddy but he's not around for a bit.

    For now I'll just deal with the squeal and hope she lasts till I can do it up properly!

  16. #16

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    Go to http://www.hollanderparts.com. They are an automotive recycler. You may have to call around but I'm sure you can find one pretty quickly.

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