Ford 5.4 3V - Front Accessory Drive Repair - Idlers, Tensioner, and Belt - Vortex Garage

This 2005 Expedition came in for a bad alternator - but as we spoke with the owner what we heard had us know right away the alternator was probably fine.
What it really turned out to be was an idler pulley that had a complete bearing failure, it came apart, and shredded the belt. This of course caused all the accessories to stop, including power steering, AC, and alternator, which the owner saw.
Rather than replace the failed pulley and belt, we took the opportunity to replace all the front accessory pulleys that are idlers or part of the tensioner. So that meant 2 smooth idlers, one grooved idler, the belt tensioner, and of course a new belt.
NOTES:
Torque Values: According to the service manual, the bolts attaching the two smooth idler pulleys, the grooved idler pulley, and the three tensioner bolts are all tightened to 18 lb ft.
Parts and Tool Links:
Note that any links to Amazon may route through our Affiliate links, which means we'll get a small comission. We do not link to items we would not buy, or haven't already bought and/or use.
PARTS:
Note - Amazon lists older part numbers for many Motorcraft parts. I ordered from RockAuto, but will post links to both there and Amazon. Just note that Amazon lists alternate numbers - ordering from Amazon.com should help ensure you get the latest part.
RockAuto - I ordered all my parts in one order from RockAuto:
Smooth Idler Pulley - Motorcraft YS385 - TWO NEEDED!:
www.rockauto.com/en/moreinfo....
Grooved Idler Pulley - ACDelco 36157 - ONE NEEDED:
www.rockauto.com/en/moreinfo....
Belt - Motorcraft JK61021A
www.rockauto.com/en/moreinfo....
Tensioner - Motorcraft BT165 (alt. part num: BT61):
www.rockauto.com/en/moreinfo....
Amazon - They use alt. part nums for some of these parts:
Smooth Idler Pulley - Motorcraft YS385 (alt. part num: YS253) - TWO NEEDED!:
amzn.to/3xJ90kn
Grooved Idler Pulley - ACDelco 36157 - ONE NEEDED:
amzn.to/3NIUfDG
Belt - Motorcraft JK61021A
amzn.to/3MJdgEv
Tensioner - Motorcraft BT165 (alt. part num: BT61):
amzn.to/3aRHVCf
TOOLS:
OPTIONAL: I used a small dab of Loctite Blue on each bolt, but there didn't appear to be any on from factory.
amzn.to/3aX2QEf
Gearwrench 57pc 3/8-drive 6pt Tool Set / Standard and Deep, SAE/Metric - 80550
amzn.to/2RSzIEG
TEKTON 3/8 Inch Drive Click Torque Wrench (10-80 ft.-lb.) | 24330
amzn.to/3yrgTcd
Thank you!
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Please be sure to see disclaimer at end of video - vid for entertainment only. Always follow your service manual and all safety precautions and local laws. This video is not a replacement for service manual, or knowledge/skills in mechanics..

[@charger6773]

Are both bolts the same length on the pulleys from the driver side? Something is telling me that one is longer than the other.

[@craigwh1000]

Your Triton 2 post lift: did you fabricate the top crossover support for the lift since it’s a floor plate lift?
I’m looking to do the same for my Atlas BP12000.
Any suggestions?
Craig

[@VortexGarage]

My apologies I missed this comment. I did fabricate it. I don't think it's necessary but it gave me some piece of mind tying the top peices together. I think it's 2" square tubing and 3/16 plate. The tube welded to the plate that is then bolted to the lift posts in existing holes.
I used thinner wall tube and it has some flex. But it's lighter. Id probably try to do 1/8 to 3/16 wall tubing. Mine may even be less than 1/8 wall but I have since forgotten the specs. Probably could ask your metal dealer what's best weight to wall thickness for the distance you want to cover. The gussets help alot. Overall it's been like this about 8yrs and working great so far.
Oh I also added the extra outriggers on the base which added more anchors to spread the load more on the floor. Another cheap insurance in my eyes.