How to Replace Pulley 02-09 Ford Explorer

Difficulty: Intermediate · About 45 min · Ford Explorer

Replace a noisy or seized idler pulley and reroute the serpentine belt on a 2002-2009 Ford Explorer.

Steps

1. Disconnect the battery

   Pull the negative terminal with an 8mm wrench before working near the pulleys and belt.

2. Move the intake hose out of the way

   Loosen the hose clamp and pop the hose free with a flat blade screwdriver, then set it aside clear of the pulley area.

3. Release and remove the serpentine belt

   Fit a 3/8 inch drive ratchet or breaker bar into the tensioner to relieve belt tension, slip the belt off, and inspect it for cracking or fraying while it is off the car.

4. Swap the idler pulley

   Unbolt the old pulley with a 15mm socket - a breaker bar or long wrench may help break a stuck bolt loose - then transfer the lock washer to the new pulley and bolt it on.

5. Reroute and reinstall the serpentine belt

   Follow the belt routing diagram on the fan shroud or under-hood sticker while relieving tensioner pressure again to walk the belt back over every pulley.

6. Reconnect the intake hose and battery

   Clip the intake hose back on and tighten its clamp, then reconnect the negative battery terminal.

Check your vehicle’s repair manual for exact specifications and fit.