So last week at 0515 I threw the drive belt on my Ford truck. I waited 2 days for a mobile mechanic to come and fix it, and so by day 3 I told him to skip it, and went to the auto parts store and bought a new one. I installed it and found that the belt was somehow misaligned and was rubbing against the belt tensioner assembly.
Turns out my harmonic balancer had crapped out and the outer pulley had come unattached to the inner pulley because the rubber moulding between each piece had gone brittle and cracked. The outer pulley was moving backwards and forwards, causing the belt misalignment and was already chewing my new $50 (AUD, around $35 USD) serpentine belt. Poop.
I rang the parts store to see if they had a new Harmonic Balancer assembly and they did ($275) and reminded me that I'd need the special puller that would allow me to remove the assembly without removing the radiator. ($275 also) I bought a new front main seal, and a couple of optional tools to remove the seal, and some degreaser and a brush.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 by
Terry Prendergast, on Flickr
I'd taken Tuesday off to do the fix, and was 'rapt that the new puller was dead easy to use, after first removing the 22mm (7/8") crankshaft bolt. It was obvious that it had been off before and someone had attempted to stem the oil leak by splotching some sealant on the back of the washer. It didn't work, there was a decent leak regardless.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 8 by
Terry Prendergast, on Flickr
Still, the bolt came out easily by attaching my long breaker bar and resting the handle on the inner frame rail, and quickly cranking the engine for a couple of turns.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 1 by
Terry Prendergast, on Flickr
The remover was apparently designed by Ford to make it possible to remove the Harmonic Balancer without removing the rad. Came off easy.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 2 by
Terry Prendergast, on Flickr
The old harmonic balancer looks pretty sad. It's a pity no-one restores them because all that's wrong with the old one is that the rubber went rock hard and cracked.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 4 by
Terry Prendergast, on Flickr
The old front crank seal popped out easily with the hook tool, so it was well worth the $20.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 5 by
Terry Prendergast, on Flickr
I had to make a little alloy drift to install the new seal, but it wasn't hard.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 5 by
Terry Prendergast, on Flickr
Falcon harmonic balancer and oil change Tuesday 23 July 2024 7 by
Terry Prendergast, on Flickr
I lubed up the new balancer, installed it, and cranked down on the crank bolt. Assembled the new, new belt (I'll keep the other one for a spare, as it's just a bit scuffed and did maybe 10 minutes worth of work) and cranked the bolt down. I couldn't work out how to stop the crank from turning so spent a couple of hours making a special tool to hold it, but it was next to useless, so I wrapped the old broken belt around the crank pulley and tied it to a frame rail, and that allowed me to crank down hard on the (loc tited) bolt to make sure it wasn't coming off.
I reassembled everything and then the Amazon man turned up with 5 litres of Gulf Western full synthetic oil ($30 AUD for 5 litres with free delivery, bargain!) a new Ryco Z9 filter and a bottle of AT-205 re-seal just in case the rear main seal was leaking. I was surprised at how thin the synthetic oil was, like water, but everyone on the Ford forums says it's good stuff, and as I don't intend to change it again for 10,000 miles, so well worth using good oil.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 9a by
Terry Prendergast, on Flickr
I drove it to work and back (54 miles) and it purred like a kitten, so I'm calling it good. Still cost over $700 (AUD, about $450 USD) but would have cost me twice that much if I took it to the shop. I celebrated by eating a "Cottage pie" for dinner.
Falcon harmonic balancer and oil change Tuesday 23 July 2024 9c by
Terry Prendergast, on Flickr