Accessory Drive Belts - Come Off Pulleys
Article No.95-5-22
03/13/95
^ ACCESSORY DRIVE BELTS - ALL 7.3L IDI DIESELS - COME OFF ACCESSORY DRIVE PULLEYS - VEHICLES BUILT AFTER 2/15/92
^ ENGINE - ALL 7.3L IDI DIESELS - FRONT END ACCESSORY DRIVE MISALIGNMENT - FEAD BELT TRACKING ISSUES - VEHICLES BUILT AFTER 2/15/92
LIGHT TRUCK:
1992-94 ECONOLINE, F-250, F-350, F-47
This TSB article is being republished in its entirety to include the latest level parts and to update the service procedure.
ISSUE:
Some diesel-powered vehicles are experiencing drive belt tracking concerns. This is caused by Front End Accessory Drive (FEAD) misalignment, which may result in the belt coming off the accessory drive pulleys. If this occurs, several warning lights will illuminate and the vehicle will lose generator and A/C function and water pump circulation. In addition, steering efforts will increase and. after one or a few brake applications, brake efforts will progressively increase.
ACTION:
Check and align the FEAD. Replace worn pulleys, A/C-P/S-V/P (air conditioner - power steering - vacuum pump) bracket and tensioner and install rubber-backed belts. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Figure 1
Figure 2
Figure 3
REMOVAL
1. Disconnect the battery negative leads from all batteries.
NOTE:
COMPONENTS INSTALLED BY FINAL STAGE VENDORS ARE NOT INCLUDED. REMOVE THOSE COMPONENTS AS NECESSARY TO CHANGE THE A/C, P/S AND V/P BRACKETS.
2. Remove the air intake tube on F-Series. Also, reduce coolant and remove the radiator top water hose.
3. Remove the fan, clutch and shroud (LH thread on tan clutch nut). Use Fan Clutch Pulley Holder T83T-6312-A and Fan Clutch Nut Wrench T83T-6312-B.
4. Remove the belt from the tensioner and discard.
5. Remove the vacuum pump and power steering pulleys using Steering Pump Pulley Remover T69L-10300-B.
6. Remove the A/C compressor, vacuum pump and power steering pump from the bracket.
NOTE:
IT SHOULD NOT BE NECESSARY TO BREAK ANY HOSE CONNECTIONS.
7. Remove the bracket, tensioner and routing idler from the cylinder head.
INSTALLATION
1. Install the A/C-P/S-V/P bracket (F4TZ-19E708-D) to the cylinder head. Tighten the three (3) fasteners to 47.5 N-m +/- 7.2 N-m (35 lb.ft. +/-5 lb.ft.). Refer to Figure 1.
2. Install the tensioner (F4TZ-6B209-C) using the T50 Torx bit and tighten to 62 N-m +/- 9.4 N-m (46 lb.ft. +/- 7 lb.ft.). The sub-bracket is attached to the flange on the main bracket adjacent to the vacuum pump location. Use two (2) new bolts (N605906-S2) and nuts (N620481-S2) and torque to 27 N-m +/- 4 N-m (20 lb.ft. +/- 3 lb.ft.).
NOTE:
THE TENSIONER LOCATING PEG MUST BE IN THE BRACKET HOLE BEFORE TIGHTENING THE TORX BOLTS.
3. Reinstall the vacuum pump. Tighten the three (3) bolts with a 10 mm socket to 27.5 N-m +/- 4.2 N-m (20 lb.ft. +/- 3 lb.ft.).
4. Reinstall the power steering pump. Tighten the three (3) bolts with a 17 mm socket to 47.5 N-m +/- 7.2 N-m (35 lb.ft. +/- 5 lb.ft.).
5. Reinstall the A/C or non-A/C idler pulley and torque to 27.8 N-m +/- 4.2 N-m (20 lb.ft. +/- 3 lb.ft.).
6. Reinstall the belt routing idler and torque to 55 N-m +/- 8.3 N-m (40 lb.ft. +/- 5 lb.ft.).
NOTE:
VERIFY THAT THE PULLEY IS CROWNED: F4TZ-8678-A. REFER TO FIGURE 1.
7. Reinstall the vacuum pump and power steering pulleys so that the pulley hub is flush to the end of the shaft 0.00 +/- 0.10" (0.00 +/- 0.25 cm). Use Steering Pump Pulley Replacer T65P-3A733-C.
8. Verify assembly sequence of Navistar shims (E3TZ-6B306-A) 0.090" (2.3 mm) at crankshaft-water pump pulleys, refer to Figure 2. The preferred assembly is with a pulley ring (E3TZ-6B306-A) in front and in back of the crank pulley and the spacer plate in front of the water pump pulley, only. Tighten to 32.5 N-m +/- 3 N-m (24 lb.ft. +/- 2 lb.ft.).
9. Install the new rubber-backed belt (F4TZ-8620-T with 130 AMP generator; F4TZ-8620-L with 165 AMP L/N generator) according to the belt routing decal.
a. Loosely route the belt over all pulleys except the routing idler. Refer to Figure 2.
b. Assure that the belt fits correctly in all grooved pulleys.
c. Swing the tensioner to the installed position and slip the belt over the routing idler.
d. Reinspect the belt fit on all pulleys.
10. Reinstall the fan/clutch and shroud using Fan Clutch Pulley Holder T83T-6312-A and Fan Clutch Nut Wrench TS3T-6312-B.
a. Tighten clutch nut to 133 N-m +/- 20 N-m (98 lb.ft. +/- 15 lb.ft.).
b. Tighten the four (4) shroud bolts to 6.5 N-m +/- 1.5 N-m (5 lb.ft. +/- 1 lb.ft.).
11. Resecure the top water hose. Tighten to 3.73 N-m +/- .61 N-m (33 lb.in. +/- 5 lb.in.).
12. Reinstall air intake tubes. Tighten to 9.0 N-m +/- 1.4 N-m (80 lb.in. +/- 12 lb.in.).
13. Service the coolant system.
PARTS BLOCK
THE ABOVE PARTS SHOULD BE PURCHASED ONLY IF FEAD BELT ALIGNMENT IS REQUIRED.
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 94-14-13
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
950522A Perform Diagnostics. 1.8 Hrs.
Replace Power Steering
Bracket, Drive Belt,
Crowned Routing Idler And
Add Fan Pulley Spacer If
Missing - F-Series
950522B Perform Diagnostics, 1.4 Hrs.
Replace Drive Belt,
Crowned Routing Idler And
Add Fan Pulley Spacer If
Missing - F-Series
950522C Perform Diagnostics, 2.3 Hrs.
Replace Power Steering
Bracket, Drive Belt,
Crowned Routing Idler And
Add Fan Pulley Spacer If
Missing - E-Series
950522D Perform Diagnostics, 1.9 Hrs.
Replace Drive Belt,
Crowned Routing Idler And
Add Fan Pulley Spacer If
Missing - Econoline
9500522E Additional Time To Replace 0.3 Hr.
Generator Bracket Or Add
Shims As Required -
F-Series
950522F Additional Time To Replace 0.4 Hr.
Generator Bracket Or Add
Shims As Required
E-Series
950522G Additional Time To Correct 0.3 Hr.
Belt Tracking - F-Series
950522H Additional Time To Correct 0.4 Hr.
Belt Tracking - E-Series
950522I Additional Time To Replace 1.1 Hrs.
Air Conditioning
Compressor - E/F-Series
950522J Additional Time To Correct 0.1 Hr.
Vacuum Pump Pulley Press
On Shaft - E/F-Series
DEALER CODING
BASIC PART NO. CONDITION CODE
8678 36
OASIS CODES: 206000, 301000, 303000, 497000