This shows the pulley we are installing. It is a red anodized aluminum pulley with 20% under drive. It can be purchased at www.underdog-performance.com
The key to not removing anything is to get the proper length of the socket. We mixed and matched what we had in the toolbox to get a measurement of 3-1/2” from the ratchet to the tip of the socket. The combo we used was a ½” to 3/8” adapter and attached a deep 13mm socket to it. This length allowed the socket to grab the bolt without hitting the fan shroud. The length of the ratchet is also critical. The ½” ratchet measured over 10”. Longer would give you more leverage. This was the longest one I had in the toolbox.
The only component we removed for access was the air intake tube between the throttle body and air box. This is easily removed with a 5/16” nut driver. The removal of the pulley consisted of two people. One above and one below. I was under the truck with the pictured ratchet while another was above the truck with a 22 mm (7/8”) wrench. He placed the wrench on the fan blade shaft to prevent the engine from turning as I loosened the bolts. I periodically instructed him to remove the wrench so I could allow the ratchet to spin the pulley (engine) to relocate the position of the bolt. If the bolt was at the high point of the pulley, the ratchet would hit the “vee” of two fan blades and it made it difficult to remove. Spinning the pulley brings it into a better position.
In the above pictures, we are loosening the bolts, not removing them. Once all of them are loose, we used a 15mm wrench to loosen the tensioner pulley and removed the belt. Once the belt was off, we removed the bolts. Working from the bottom, I was able to pass the pulley up the engine bay to my helper. There is an opening on the passenger side that you will see. He then sent the under drive pulley to me through the same passageway. We worked together to get the 4 bolts started. Take your time and don’t get frustrated. I used my bare hands to start all 4 of the bolts. He assisted by holding the pulley in place when needed. I snugged down 2 bolts that were diagonal to each other. Don’t worry about getting them all snug. Sometimes one will go easy and another will be tight. Just move on to the next one. The goal is to get 2 of them snug so you can install the new belt. We used a gatorback belt #4060872. Once the belt is on, your helper can once again use the wrench on the fan shaft to keep the engine/pulley from spinning. As before, you will instruct him to remove the wrench to put the bolt in a position to tighten it down. Make sure all 4 bolts are tight. 45 pounds is the recommended torque.
You are almost done. Reinstall the air intake tube and start it up to make sure everything looks good. I hope it went as easy as it did for me. Let me know.