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I fixed my Harmonic Balancer, now the car stalls with 20 error codes

Discussion in 'Stock 2002 - 2005 Explorers' started by rob909e, August 31, 2018.

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    1. rob909e

      rob909e New Member

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      Year, Model & Trim Level:
      2005 Ford Explore 4.0
      I broke down and took the Explorer to Apple Ford and after 4 days I haven't heard anything from them. Before I took it in, I went over everything I worked on, making sure everything was put back right and working. It's only got about 60k miles on it, never got in an accident, and has had nothing wrong with it, except for the Harmonic Balancer. This is EXACTLY what I did on my Explorer, in order.

      1. Disconnected the Battery.
      2. Removed the top plastic part of the fan shroud
      3. Disconnected and took out the fat hose from the radiator
      4. Disconnected the small hose from the radiator to the reservoir
      5. Drained the radiator via the bottom drain plug on the radiator.
      6. Took off the fan with cluch nut
      7. Unhooked and removed serpentine belt
      8. Removed Idler pulley
      9. Removed tensioner pulley
      10. Removed Fuse/Relay #49 Highbeam (by accident)
      11. Removed Fuse/Relay #48 Fuel Pump Relay.
      12. Loosened the Crankshaft bolt of the harmonic balancer. (Center bolt)
      !NOTE! Reconnect Battery.
      In order for me to loosen the bolt, I had to use a braker bar and extender, and then start the engine for a second to loosen it. THIS WAS THE ONLY WAY for me to free the bolt.
      Disconnect Battery
      13. Using the Harmonic Balancer Universal Puller kit from Autozone, I began the process of pulling the harmonic balancer off the Crankshaft.
      14. Once the Harmonic Balancer was 99% off the crank, I ran out of threads on the balancer bolt to use as leverage to pull the balancer off the rest of the way. So I had to take the puller completely off the balancer, then remove the crank shaft bolt completely. Then using a longer bolt I had lying around my house, I stuck that inside the crankshaft, through the balancer, until it hit whatever was on the otherside. I put the puller back onto the harmonic balancer and used the longer, thinner bolt as leverage to get the balancer off the rest of the way.
      15. Once the balancer was off the crank, I took out the makeshift bolt out of the crankshaft.
      16. Installed new Idler pulley.
      17. Installed new tensioner pulley.
      18. greased the outter part of the new harmonic balancer, lined up the keyway slot and racheted on the new harmonic balancer.
      19. Put new serpentine belt on.
      20. Torqued the center crankshaft bolt to about 30-40lbs, (that's all I could manage using a strap wrench before it would spin under the weight)
      21. Reinstalled the fan and clutch bearing
      22. Reinstalled both the fat and skinny hose back to the radiator.
      23. Reinstalled the fan shroud
      24. Filled the radiator with about 3 gallons of Ford radiator fluid.
      25. Tried to start the car but it wouldn't start (forgot to put back both Fuse/Relay #48 and #49)
      26. Put Fuse/Relay #48 and #49 back in and car started up.
      27. Let the car run for about 5 min, all seemed great.
      28. Turned off the car after the engine was good and warm.
      29. Changed oil, oil filter, and air filter.
      30. Went out for a test drive -
      a. Car stalled out and would not accelerate. On the dashboard, the wrench icon lit up and the display panel said the car was put into ETC Engine Failsafe mode. This now happens EVER TIME the car is driven.
      31. Hooked up the Explorer to a OBD-II reader and recorded all codes. (THEY ARE INCLUDED IN THIS THREAD)
      32. Removed the Throttle Body, Cleaned the ThrottleBody and the sensor.
      33. Installed Throttle Body.
      34. Test drive revealed exact same results listed in 30.a

      Below is a picture of the components I removed in the process of this repair. ANY ADVICE would be appreciated.

      . 71861825.jpg
       
      Last edited: October 15, 2018 at 1:39 PM
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    3. massacre

      massacre Elite Explorer

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      Have you replaced the crank sensor or checked the sensor wiring?
      Sounds like the crank sensor and throttle body sensor are not jiving.
      My Haynes manual has procedures to test the various sensors, you can check most of them with a cheap digital volt meter.

      [​IMG]

      Since the throttle body sensor reads a mechanical motion, make sure the TB is opening properly and not binding up somehow or the cable is not binding as well.
      That’s where I’d start. Then at least you will know what is working correctly and what isn’t.
       
    4. vipersinu2

      vipersinu2 Active Member

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      did you change the spark plugs? Maybe you were sold the wrong plugs.
       
    5. rob909e

      rob909e New Member

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      UPDATE: Ford called, and the person I spoke to said it sounds like a bad Harmonic Balancer!?! LOL. I told him I replaced the harmonic balancer! He asked where I purchased it from. I told him, from your dealership, Apple ford. He replied, oh. Then he said, let me talk with the Mechanic again. I asked if I could talk directly to him. He said no. I told him that when I checked the computer with a OBD-II code reader, the Explorer triggered 20 OBD-II codes.
       
    6. rob909e

      rob909e New Member

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      Didn't change the Spark Plugs.
       
    7. 974X4BLACKSPORT

      974X4BLACKSPORT Active Member

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      In your procedure list of changing the balancer, how did you perform step #12, after step #1?
       
    8. Mbrooks420

      Mbrooks420 High Voltage. Elite Explorer

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      I assume he hooked it back up to run the starter.

      Did you do anything with the crank sensor? I’d have tested or replaced it before taking it to a dealer.
       
    9. rob909e

      rob909e New Member

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      Good eye. I changed it.
       
    10. rob909e

      rob909e New Member

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      The Crank Sensor? Is that the Black plastic object pointing directly at the Harmonic Balancer? If so, I left it on throughout the entire process.
       
    11. rob909e

      rob909e New Member

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      Here's the part I Ford Sold me to replace my old harmonic balancer

      [​IMG]
      HBR.PNG
       
    12. Mbrooks420

      Mbrooks420 High Voltage. Elite Explorer

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      Yes, the crank sensor reads those teeth. I’d replace it if the wires look good.
       

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