First Post, and a thanks to all!
The balancer in my 2005 failed the other day. It started with the usual squeak. I, like many others here, replaced the belt, and the squeak went away for a short time. The chirping returned, but louder. The noise seemed to be rpm related, so I assumed the alternator bearings had failed. I observed the tensioner bouncing, as others have. I removed the new belt, and turned the alternator by hand. It seemed to squeak when turned in one direction. I should have observed the noise was present when turning the pulley in the wrong (counter-clockwise) direction. I researched the parts, and was prepared to R and R the alternator. While on a short errand to procure some parts, I started the Ex, and upon turning the steering wheel, got a charging system error, which promptly went away.
I had my g/f turn the wheel, with the lights and A/C on. The entire belt system would completely stop for 1/2 second immediately as the wheel was turned.
When we returned home, I removed the belt again. Every pulley seemed OK. However, when I attempted to thread the belt back around the bottom of the crank pulley, the outer ring, where the belt rides, turned without turning the engine!
I have the failed balancer/pulley.
Called Dorman. I was told the 4.0 pulley P/N: 594-111 which they have listed, will not work on the later SOHC.
Finally called the local dealer. There is a new style pulley from Ford. P/N: 8L2Z-6B321-A retails for $198.91.
I picked it up, and ordered a replacement bolt. I removed the defective balancer using the process others have perfected here on ExplorerForums.
This work included the starter bump/breaker bar method for bolt removal. I disconnected the coil pack wiring connector, as well as removed the crank position sensor, to prevent starting, and damage to the sensor. I covered the radiator to protect it as well. Works excellent!!
I'll get it finished when the new bolt arrives on Monday.
Pictures for now:
New part on the right. There is a huge change, the outer hub is now fully vulcanized to the inner hub.
The exciter ring is totally different.
Another view.
Close up of the failed bonded joint.
I'll update when I am finished.
Sean