Broken Idler Pulley Bolt

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Cody Glyn-Jones

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Ive got an 04 XLT 5.4l. Replacing idler and tension pulleys. Was installing grooved tensioner pulley on the driver side. Bolt was pretty tight but there was still wiggle in the pulley, so I proceeded to tighten it more. So much so that I sheared the bolt off. I dont think theres enough room between the bolt and radiator to get a drill in there to drill it out. Is there a way to get it out without having to unbolt and lift the entire engine? Is it possible to get to it through the front by removing the fan, radiator, and grille? Is it possible to get to it without doing any of these things at all? Does anyone have experience with this? Any help at all is very appreciated..
 
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ManUpOrShutUp

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I don't have an '04, but I know on the '00 you can open up a ton of space by removing a few items.


You should be able to get a screw extractor in there that way or maybe even without doing any of that if you have a right angle adapter. Grab a torque wrench while you're at it. :D
 

Hamfisted

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Holy crap. I think that's a new one. But yeah, you probably need to remove the fan and radiator to do the job. I would get an angle drill and left hand drill bit, and screw extractor kit. Take your time and make sure you are centered on the broken bolt before doing any drilling. Hopefully with the left hand drill bit the bolt will start to unscrew as you're drilling. You might need to run a tap back through the bolt hole to clean up the threads when you're done. If you booger it up you just end up replacing the timing cover. I don't know if the dealer is gonna have that flange head bolt in stock. Use a torque wrench whenever a torque is specified for a fastener.

Idler Pulley Bolt...
https://www.fordpartsgiant.com/part...&location=engine/pulleys_and_drive_belts,,HM1


https://www.homedepot.com/p/DEWALT-...6952413-92700060764889411&gclsrc=ds&gclsrc=ds


https://www.homedepot.com/s/Left%20hand%20drill%20bit?NCNI-5

https://www.homedepot.com/p/General...nch-with-Replaceable-Steel-Point-78/301345941


https://www.homedepot.com/p/GEARWRE...-lbs-Electronic-Torque-Wrench-85076/310123712
 
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