Idler Pully problem.
Discussion
Guy's, some help/information please.
Just undertaken some suspension/AC compressor work on the rear of my 2002 2.5 M12 and when replacing the auxilliary drive belt I noticed that the idler pully was at an angle to all the other pulleys. Nothing I have done in replacing the AC compressor would have been enough to bend the pump/alternator mounting bracket or bush (which is probably the most solid bit of metalwork I come across so far!!). I replaced the belt an ran the engine up only for it to move across towards the edge of the pulley so it overlaps about 4 - 5mm at it's worst point, and starts squealing. Turn the engine off and the belt moves back. I've tried moving the belt across on the AC pully, but the squealing remains. It didn't squeal before but I can't recall ever looking at the belt and seeing it move.
Having removed the pulley, the bearing looks Ok, although it is weeping a bit of grease, the bolt is slightly bent, but when tightened up the pully runs true but still at an angle. The main problem seems to be the bracket bush which looks to be machined at an angle. See pic's below. Should the pulley be at an angle or is the bush knackered?
Just undertaken some suspension/AC compressor work on the rear of my 2002 2.5 M12 and when replacing the auxilliary drive belt I noticed that the idler pully was at an angle to all the other pulleys. Nothing I have done in replacing the AC compressor would have been enough to bend the pump/alternator mounting bracket or bush (which is probably the most solid bit of metalwork I come across so far!!). I replaced the belt an ran the engine up only for it to move across towards the edge of the pulley so it overlaps about 4 - 5mm at it's worst point, and starts squealing. Turn the engine off and the belt moves back. I've tried moving the belt across on the AC pully, but the squealing remains. It didn't squeal before but I can't recall ever looking at the belt and seeing it move.
Having removed the pulley, the bearing looks Ok, although it is weeping a bit of grease, the bolt is slightly bent, but when tightened up the pully runs true but still at an angle. The main problem seems to be the bracket bush which looks to be machined at an angle. See pic's below. Should the pulley be at an angle or is the bush knackered?
if the bracking is not sitting the pulley true to the belt then it must be knackered IMO... there is a brace for the bracket by the exhaust manifold, is this still present and true?
Its only a mild steel bracket and I have modified mine a bit so it isnt a hard job to put right, just cut off and weld new thread in correct possition and angle.
Its only a mild steel bracket and I have modified mine a bit so it isnt a hard job to put right, just cut off and weld new thread in correct possition and angle.
Not really relevant, but my US-built 3.0 has the same problem. The bracket does not have a threaded boss, rather there is a surprisingly long bolt and nut. I'm not sure exactly what is causing the misalignment, but it's easy to see that the idler is canted compared to the other pulleys. It must have been so from the beginning because the installer added ordinary washers to space the pulley out a bit. I guess they figured the owner wouldn't mind a new belt every few thousand miles.
Jeff
Jeff
My son and I removed the bracket this afternoon - basically took off everything we had just put back on! Luckily I hadn't had the A/C charged yet. Anyway, now it's off, there seems to be no way you could accidentially bend the boss, it's pretty substantial, and would take a great deal of force to bend it so it must have been on pi$$ before I bought the car.
Now I have it on the bench, it looks like the end of the boss has been beaten with a hammer - it's probably got a 15 deg angle on it! The (pretty bad!) pic below hopefully show it.
My son thinks he may have one the same at work so he is bringing it back tomorrow with the box. If it's the same I'll post the part number in the Wiki.
The light mark under the pulley is the gap
Now I have it on the bench, it looks like the end of the boss has been beaten with a hammer - it's probably got a 15 deg angle on it! The (pretty bad!) pic below hopefully show it.
My son thinks he may have one the same at work so he is bringing it back tomorrow with the box. If it's the same I'll post the part number in the Wiki.
The light mark under the pulley is the gap
Took it to my local engineers shop today. They are going to mill it flat. The guy there said it looked from the marks on the bush that it had been cut to that angle - whoever did it must have been well pi$$ed when they used the saw!
Still trying to source what the pulley is off though - back to the Ford garage tomorrow to collar their mechanics and parts computer!
Still trying to source what the pulley is off though - back to the Ford garage tomorrow to collar their mechanics and parts computer!
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