We had a goal of installing an under drive pulley on a 3.0 Ranger WITHOUT removing the fan or shroud. I have read where some went to the extent of removing their radiator to get the pulley on. We smarted our way through it and came up with this install how-to. I hope it helps.

This shows the pulley we are installing. It is a red anodized aluminum pulley with 20% under drive. It can be purchased at www.underdog-performance.com

http://www.mustangmods.com/data/7208/hpim2102.jpg

The key to not removing anything is to get the proper length of the socket. We mixed and matched what we had in the toolbox to get a measurement of 3-1/2” from the ratchet to the tip of the socket. The combo we used was a ½” to 3/8” adapter and attached a deep 13mm socket to it. This length allowed the socket to grab the bolt without hitting the fan shroud. The length of the ratchet is also critical. The ½” ratchet measured over 10”. Longer would give you more leverage. This was the longest one I had in the toolbox.

http://www.mustangmods.com/data/7208/hpim2099.jpg

The only component we removed for access was the air intake tube between the throttle body and air box. This is easily removed with a 5/16” nut driver. The removal of the pulley consisted of two people. One above and one below. I was under the truck with the pictured ratchet while another was above the truck with a 22 mm (7/8”) wrench. He placed the wrench on the fan blade shaft to prevent the engine from turning as I loosened the bolts. I periodically instructed him to remove the wrench so I could allow the ratchet to spin the pulley (engine) to relocate the position of the bolt. If the bolt was at the high point of the pulley, the ratchet would hit the “vee” of two fan blades and it made it difficult to remove. Spinning the pulley brings it into a better position.

http://www.mustangmods.com/data/7208/hpim2096.jpg

http://www.mustangmods.com/data/7208/hpim2093.jpg

In the above pictures, we are loosening the bolts, not removing them. Once all of them are loose, we used a 15mm wrench to loosen the tensioner pulley and removed the belt. Once the belt was off, we removed the bolts. Working from the bottom, I was able to pass the pulley up the engine bay to my helper. There is an opening on the passenger side that you will see. He then sent the under drive pulley to me through the same passageway. We worked together to get the 4 bolts started. Take your time and don’t get frustrated. I used my bare hands to start all 4 of the bolts. He assisted by holding the pulley in place when needed. I snugged down 2 bolts that were diagonal to each other. Don’t worry about getting them all snug. Sometimes one will go easy and another will be tight. Just move on to the next one. The goal is to get 2 of them snug so you can install the new belt. We used a gatorback belt #4060872. Once the belt is on, your helper can once again use the wrench on the fan shaft to keep the engine/pulley from spinning. As before, you will instruct him to remove the wrench to put the bolt in a position to tighten it down. Make sure all 4 bolts are tight. 45 pounds is the recommended torque.
http://www.mustangmods.com/data/7208/hpim2104.jpg
http://www.mustangmods.com/data/7208/hpim1105.jpg

You are almost done. Reinstall the air intake tube and start it up to make sure everything looks good. I hope it went as easy as it did for me. Let me know.

Before and after:
http://www.mustangmods.com/data/7208/underdog_pulley_3.0l_ford_ranger.jpg


Edit: If you WANT to remove the fan, go here (http://www.cardomain.com/ride/2384970/2)...

I just installed mine on my Edge and it was pretty easy. The hardest part was removing the bolts. They have loctite on them so that made it extra hard to remove them. I recomend cleaning the hole and the damper with carb cleaner to disolve the left over loctite or any other debris around there. In my case it was full of dirt plus the loctite that made the job a lot harder when it came to installing it. I also recomend doing the e-fan install at the same time. The truck feels a lot better with these mods and I totally recomend them.

Tomas
2001 Edge

Were you able to find a gatorback belt, or did you use a different brand? Glad it all went well for you. If you removed the locktite off the bolts also you may want to check the pulley periodically to make sure the bolts don't back out. Just pop the hood while it is idling and see if there is a wobble.

I hope your dad enjoys the benefits.

I bought a Dayco 87" at a local parts store. I also put some new loctite after I cleaned them. This way they went in much easier. Thanks for all your help and excelent service.

Good writeup. Was a big help. Thanks!

I just installed a pulley in a '99 ranger 3.0. It sure seemed like it had a lot more room than the others I have installed. This is the only coil front end I have done, the rest have been torsion bar Edge models. It went so easy that I didn't need a helper. I could hold the belt from underneath to torque the bolts down when needed. Very Very easy install.

Just wanted to post what I thought about my new Underdog Pulley. Enjoyed the forums here for quite some time. I use to post under "Bulldog Swamping" or something like that. Its been a while.

Overall I think the UD pulley is a great buy and is worth every penny. From tracking my shipment to extra tips on instillation Underdog was great. The gatorback that was sent fit just right.

On the install I would suggest getting someone to help you if you can. I went solo on the removal of the stock pulley so it took probably 45 minutes or so to do just that.

Seemed like there was a ton of locktite on the bolts and inside the threaded area so that was a bit of an aggervation. The instructions posted on what wrench and sockets to use are right on the money.

Getting the UD pulley back on was no sweat, just be patient getting those bolts started and they will get in there sooner or later. I got my Dad to hold a wrench on the fan shaft so I could torq down the pulley properly and it was all over with.

All in all its an easy mod and I suggest anyone with a 3.0L buy an Underdog or a DZK pulley.

I definetly feel a difference on acceleration and it hangs in 5th/OD alot longer when climbing grades. Driving from Atl to Gainesville I managed to get 318 miles with my gas hand a hair above the red (16.5 gal tank) and that was at 80 mph. At idle my charging is below where it once was but as soon as you start driving its back to where it normally stays so no problems there. Best mod for the buck IMO.

Sorry this was so long!!

I think this is the better place for this, also I would say go ahead and replace Idle pulley while your at it.

FYI because it took me awhile to find this in a search, to loosen the belt tension just use the 15mm socket/wrench on the lower tensioner pulley bolt (in the middle of the pulley itself) to swing the pulley sideways hence releive pressure on the belt. Its an autotensioner which if you normally work on imports is rare for an accessory belt tensioner.

Also, it is easily done with no help if you have a 5 speed. Just drop it into second with the parking brake on; the pulley itself came out easily from the bottom on my torsion bar b3000 dual sport (i.e. edge). I also had no need to remove the intake tube, probably because its a 5 speed.

Overall, definately one of the best bang for the buck mods ever. Noticeble difference, much quieter at idle, extremely cheap and easy, and no sacrifice in reliability since the harmonic balancer is separate and retained.

Mike

Thanks for the excellent write-up. Installed my new pulley and belt on Saturday, it went pretty smoothly. The worst part by far was taking out the old bolts. Mine were in there pretty freakin good, Id reccomend spraying something on them a few hours before you start just to help. PB blaster is always good. Other than that the new pulley and belt went on fine. Thanks underdog for a great pruduct! It looks good and performs alot better. And of course the squeaky belt is finally gone! :burnout:

Sorry if this is a stupid qestion :confused But do you need to also use a differnt belt (or size) or the original belt can be reused( just got a brand new belt) Thanks guys

Cody

ok im an idiot after i read the thread a little closer i see you need a new belt but i can only find the gator belt with ac. Will it make a differnce if i dont have ac and what would be a replacment belt?

ok im an idiot after i read the thread a little closer i see you need a new belt but i can only find the gator belt with ac. Will it make a differnce if i dont have ac and what would be a replacment belt?
Look here:
http://www.rangerpowersports.com/forum/showpost.php?p=1102643&postcount=8

All the belt info...

thanks for the help man, i tried the search but came up with nothing but info that i already knew.

Cody

Hey, no prob, we've all been there.

Just installed my underdog pulley, and I am please with the results. You can tell a difference! Excellent write up.

Very nice writeup!

Now if you can excuse my ignorance (I'm new to Rangers and performance), how does an underdrive pulley improve performance? Seems to me it would cause the accessories to spin slower at any given RPM. This helps somehow? I'll be installing my Whipple unit in two weeks as well... would this hinder my HP gains with a belt-driven blower?

I've ordered the pulley and belt yesterday.I'm not going to be able to install till maybe end of year.But when I do I'm also installing a E-fan.I'll post results after mod is complete. :driving:

Very nice writeup!

Now if you can excuse my ignorance (I'm new to Rangers and performance), how does an underdrive pulley improve performance? Seems to me it would cause the accessories to spin slower at any given RPM. This helps somehow? I'll be installing my Whipple unit in two weeks as well... would this hinder my HP gains with a belt-driven blower?

With a whipple you would not want an underdrive crank pulley. It would do as you say, slow down the supercharger which translates to less boost/less HP.

just to recap if i install the underdrive pulley could i still use my stock belt or do i have to use a shorter 87"?

You will need a shorter belt. You can find less expensive ones than the gatorback if you look around.

where do you order the belt and pully, well in easier words, everything i would need to do it