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Old 03-15-2011, 06:12 PM
RLong31 RLong31 is offline
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Default How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Written by: RLong31

How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Tools Required: 7mm socket
8mm socket
10mm socket
13mm socket
15mm socket
19mm socket
24”+ Breaker bar or Impact wrench
” socket wrench
3/8” socket wrench
” socket wrench
Flathead screwdriver
Adjustable strap wrench
Harmonic Balancer Puller Tool (or something similar)(Rent at PepBoys/Autozone)
Fan Clutch removal tool (rent at PepBoys/Autozone)
Lots of Patience
Beer

Materials Needed: 4.0L 5 piece Underdrive Pulley Kit from Underdog Performance @ www.stuffforyourranger.com to include :

4.0 ASP Underdrive Crank Pulley
4.0 Underdrive Water Pump Pulley (red or blue)
4.0 Overdrive Alternator Pulley (red or blue)
4.0 Stock sized Idler Pulley (red or blue)
4.0 Stock sized Water Pump Pulley (red or blue)

Gatorback belt : Part # 4060865 (Ordered mine from Amazon)
Crankshaft bolt : Ford Part # E7RY6A340B

This How-To MIGHT help:
http://stuffforyourranger.com/How_To...nderdrive.html

Time Required: 3-6 hours

Difficulty: Moderate-Difficult (5-8) LOL 

Step 1: Remove the intake cover – 3 bolts – 7mm



Step 2: Unclip air box, loosen hose clamps on air intake hose (flathead) and remove intake hose and air box lid



Fan Clutch removal tool : You will use the 57mm and 36mm wrenches


Step 3: Put the 57mm fan clutch wrench around the 4 bolts that hold the water pump pulley on. Then put the 36mm wrench on the nut for the fan. Loosen the fan by pushing the 57mm to the right… 36mm to the left. It will take some muscle to break it free. Spin fan until it comes off of the water pump pulley.





Step 4: Remove 2 bolts holding on the fan shroud (10mm)



Step 5: Pull Up and remove Fan shroud and Fan


Step 6: Using a 3/8” socket wrench, put it into square hole on belt tensioner and push down to loosen tension on belt; then remove the belt


NOTICE: At this point, I had already installed the Stock sized Idler pulley and the stock-sized water pump pulley (3 bolts) on an earlier install attempt. I will include the steps, but there are no pictures.

Step 7: Using a 15mm socket, remove the stock idler pulley.

Step 8: Install aftermarket Stock-sized idler pulley.

NOTICE: You will need to re-use the bolt, but I had to remove the washer on the outside part of the pulley because it was getting caught on the lock-ring on the new pulley and wouldn’t allow it to spin.


Step 9: Using a 10mm socket, remove the stock water pump pulley (3 bolts). You can use a flathead screwdriver… or a strap wrench to hold the pulley from moving while you loosen the 3 bolts holding the pulley on. Pull hard, the pulley will come off.

Step 10: Install aftermarket Stock-sized water pump pulley (3 bolts). It might be difficult to install, but just tighten the bolts like you would a tire… it will get on there eventually.

Step 11: Use the 57mm fan clutch wrench and a 10mm socket to remove the 4 bolts holding the stock water pump pulley (4 bolts) off.



Step 12: Install new Underdrive Water pump pulley with 4 bolts. (Sorry, No picture)

NOTICE: This is where things can get difficult, especially if you do not have the right tools, and a good friend to help.

Step 13: Using a 19mm deep socket, and a large breaker bar, place the socket on the crankshaft bolt (inside the hole on the crankshaft pulley) and rest the breaker bar on top of the driver side of the frame. Go into the cab, and turn it over to “bump” the starter… DO NOT CRANK THE MOTOR. This should break the bolt free, and you can loosen it the rest of the way by hand.

NOTICE: You can break the bolt free by using a strap wrench and a LOT of muscle to break it free, the bolt is torqued on and very difficult to break free. OR.. you can try to fit an impact wrench on there if space permits (might need to remove the radiator).


Step 14: Using a 8mm socket, remove Crankshaft Position Sensor (2 bolts). Then pinch the metal clip and pull sensor off of the wiring harness.

NOTICE: You want to remove this because it can be broken easily, and your engine will not start if it is not there… ask me how I know.



Step 15: Remove pulley using a harmonic balancer removal tool. Different "stud" lengths will be helpful as the clearance is tight between it and the radiator.

NOTICE: You will use the bolts that come with the kit. Most puller tools don’t have long enough bolts, even the universal ones.



Note the difference in size between the stock crank pulley and the underdrive pulley. Stock pulley on the left, underdog pulley on the right.



Step 16: Remove plastic collar from original pulley and install it in underdog 4.0 pulley. I used the puller tool, but a flat tip screwdriver will suffice. Be careful not to break it. Install this piece on the new pulley.



Step 17: Prep the new pulley per directions included with the kit. RTV Silicone and grease will be needed. I marked the key slot on the exterior of the pulley with a grease crayon. This made positioning the pulley onto the crank shaft easier. You can "bump" the starter to move the keyway into a more visible location.



Step 18: Set the pulley onto the shaft so that the keyways are line up. Insert the enclosed longer pulley bolt (included in the kit) and screw it about half way down. Remove this bolt and install the original crank bolt until tight.

Step 19: Wrap your adjustable strap wrench around your new pulley to hold it tight from moving. Using your torque wrench, tighten the new crank bolt to specs (80 ft/lbs).

Step 20: Install your new belt by loosening tension on the tensioner.

NOTICE: You should have a drawing of how your belt should be ran on top of your header panel.

Step 21: Re-install fan and shroud.

Step 22: Re-install intake and cover.

THE END

End Result:


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2004 Ranger Edge 4x4, 4.0L SOHC, 4.10's, Black, Step-Side Bed, Quad Cab, 3" PA Body Lift, Underdrive Pulleys, Flowmaster 40 Catback, Mustang GT Disc Brakes
33x12.5 Goodyear Duratracs, 15x8 MB Motoring Overdrives, STX/Sport Grille, Explorer OHC & Auto-Dimming Mirror, Blacked Out Headlights & Corners,
Smoked Altezza Tail Lights, 35w 4500k Hi/Low HID Heads & Fogs, Hella 500ff's, Ultra-Gauge, Red LED Interior

Last edited by RLong31; 03-15-2011 at 06:32 PM.
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  #2  
Old 03-15-2011, 06:59 PM
DiabloBlanco DiabloBlanco is offline
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Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Outstanding writeup!
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Mods to come: Camburg entry 6.0 system. FiberwerkX Fenders and bedsides. Tube bumper.
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  #3  
Old 03-15-2011, 07:15 PM
RLong31 RLong31 is offline
They call me T-Dawg yo
 
Join Date: Jan 2011
Posts: 263
Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Thanks. This mod is kind of a pain in the ass. Hope this resource helps any and all who try this.
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2004 Ranger Edge 4x4, 4.0L SOHC, 4.10's, Black, Step-Side Bed, Quad Cab, 3" PA Body Lift, Underdrive Pulleys, Flowmaster 40 Catback, Mustang GT Disc Brakes
33x12.5 Goodyear Duratracs, 15x8 MB Motoring Overdrives, STX/Sport Grille, Explorer OHC & Auto-Dimming Mirror, Blacked Out Headlights & Corners,
Smoked Altezza Tail Lights, 35w 4500k Hi/Low HID Heads & Fogs, Hella 500ff's, Ultra-Gauge, Red LED Interior
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  #4  
Old 08-04-2011, 12:00 AM
huskerman16 huskerman16 is offline
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Posts: 522
Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

what are the gains from doing this?
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  #5  
Old 09-16-2011, 01:07 PM
RLong31 RLong31 is offline
They call me T-Dawg yo
 
Join Date: Jan 2011
Posts: 263
Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Sorry I never noticed the response on this thread. The gains are minimal. Slight mpgs increase and maybe a few horses freed up due to less drag on the motor, but with a lead foot it's probably un-noticeable. Also you can kind of feel a "seat of the pants" increase... feels like it takes off faster. Not huge gains, but it's noticeable. I never had it dynoed before or after... so no real numbers for you.

My main reason for doing this was my stock crank pulley has the harmonic balancer built into it. Well, over time there is sort of a heavy "washer" inside it that broke free and was rattling around as the crank spun... caused a loud rattle that drove me nuts. I figured if I was going to spend the coin to replace it, I might as well upgrade.

Any questions, let me know. As far as I know.. Underdog Performance is no longer in business. Wayne might still have some stuff left over, so it's worth it to contact him through the website listed above. The pulley can be custom ordered from ASP Racing... google them. They should be able to duplicate a kit, although the price might be more.
__________________
2004 Ranger Edge 4x4, 4.0L SOHC, 4.10's, Black, Step-Side Bed, Quad Cab, 3" PA Body Lift, Underdrive Pulleys, Flowmaster 40 Catback, Mustang GT Disc Brakes
33x12.5 Goodyear Duratracs, 15x8 MB Motoring Overdrives, STX/Sport Grille, Explorer OHC & Auto-Dimming Mirror, Blacked Out Headlights & Corners,
Smoked Altezza Tail Lights, 35w 4500k Hi/Low HID Heads & Fogs, Hella 500ff's, Ultra-Gauge, Red LED Interior
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  #6  
Old 11-01-2011, 12:07 AM
greenmachine2000 greenmachine2000 is offline
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Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

what kinda belt you have on your truck?? looks sweet.
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oops! 2000 4x4 4.0 8.8 3.73 gears 7 inches of lift 4 suspension and 3 body. 33x12.50.15 bfg all terrains. CB MORE TO COME. IMO im always right.
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  #7  
Old 11-01-2011, 06:56 AM
RLong31 RLong31 is offline
They call me T-Dawg yo
 
Join Date: Jan 2011
Posts: 263
Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

The belt looks sweet? Okaaaaay... lol

Gatorback belt : Part # 4060865 (Ordered mine from Amazon)
__________________
2004 Ranger Edge 4x4, 4.0L SOHC, 4.10's, Black, Step-Side Bed, Quad Cab, 3" PA Body Lift, Underdrive Pulleys, Flowmaster 40 Catback, Mustang GT Disc Brakes
33x12.5 Goodyear Duratracs, 15x8 MB Motoring Overdrives, STX/Sport Grille, Explorer OHC & Auto-Dimming Mirror, Blacked Out Headlights & Corners,
Smoked Altezza Tail Lights, 35w 4500k Hi/Low HID Heads & Fogs, Hella 500ff's, Ultra-Gauge, Red LED Interior
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  #8  
Old 11-03-2011, 10:39 AM
texperry texperry is offline
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Join Date: Oct 2011
Posts: 22
Post Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

ok i got a puller from advance auto but its a bit different it has to arms that latch onto the back of the pulley and we've drivin the center bolt as far into the center as we think itl go before it tears the gasket and really messes things up. are we doin something wrong? the thing has to come out because a gasket broke behind the timing cover and it leaks water.
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1991 Ranger Supercab STX 4x4 4.0l OHV Automatic

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  #9  
Old 09-30-2014, 04:22 PM
JC2on JC2on is offline
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Default Re: How-To : 4.0L SOHC/OHV Underdog Underdrive Pulley Kit Install

Hi, I know this was long ago. I did my Harmonic Balancer replacement, but now my ranger wont start up. Replaced crank sensor, nothing again. Any suggestions? did I messed up the timing when re-installing?
if so, how do I set the timing?

thanks!!!!
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