Installing the ASP 4.0 underdrive crank pulley

By Todd Zabbia

This Project will help you install The ASP 4.0 under drive pulley On a Sport Trac.

I am rating this a 4 Wrench project. It is not recommend for the basic do it your selfer and requires more than simple tools. The Extra tools needed can be rented cheaply or bought for under $50.00 dollars.

TRUCKS WITH A LOT OF ELECTRONICS it is recommended that after you install this you check your charging system with all the electronics on to check that the alternator is able to keep up or you may cause damage to your electronics.

A pulley for the alternator is in testing at this time

The tools needed are more than a basic socket set , screw drivers and wrenches.

You will also need a serpentine belt tool ( Or you need a long 3/8 ratchet), Clutch fan removal tool, torque wrench and a harmonic balancer pulley puller.

First disconnect the negative battery cable.

Next remove the 4.0 plastic cover and the air intake tube.

On my truck I have an aftermarket intake. The stock one is a rubber tube.

Now to remove the fan shroud and clutch fan. First locate the fan nut.

Using the tool loosen the nut counter clockwise. ( right hand thread)

You will start to see the threads. It will take a lot of turns to remove the fan nut off the water pump. Be careful not to let the fan hit the radiator, this could cause damage. Once off let it sit inside the fan shroud.

Now remove the top 2 - 10 mm bolts holding the shroud on.

It may also be necessary to remove the top transmission cooling line to allow the shroud to come out. When doing this use 2 wrenches, the adaptor must stay in the radiator, and the line nut will come off. A drop or two of fluid may leak.

Then Remove the fan and shroud.

Now remove the lower splash shield ( I did this first)

Next loosen the crank pulley bolt ( 19 mm )

You may need an impact gun if you cant hold the pulley from turning. DO NOT let it turn, you can damage the engine. My impact gun would not fit so I used the 2 bolts supplied with the new pulley and my fan clutch tool to hold the pulley and the nut came right off.

Now locate the belt tensioner and remove the belt.

Note the way the belt is wrapped. There is a decal on the radiator support.

You are now ready to remove the old pulley. Using your puller remove the pulley. You may need different length bolts as the radiator is close. Some of the pullers have large center pins, In this case it will be easier to remove the factory bolt completely and using the bolt that came with the pulley, Thread it in 3 turns or so, and let the center bolt of the puller push against the head of the bolt. This will allow the pulley to slide off. Once the pulley is removed you will see an oil slinger on the old pulley.

You may need different length bolts as the radiator is close.

Once the pulley is removed you will see an oil slinger on the old pulley.

This is plastic and can break. Remove it by pulling straight up. A small screwdriver may be used to slightly pry it up.

Once removed, clean it and press it on to the new crank pulley. NOTE the way it faces.

Now as per the included instructions lightly grease the inside and out side of the pulley shaft, and place a little silicone in the key way slot to prevent any oil leakage. Also place a little grease on the silver washer inside the pulley.

Here is the new pulley with the ring on, grease on the shaft and a little silicone in the key way. This will prevent any oil seepage.

In the above picture You see the one tooth missing on the side of the pulley

This is where the key way slot is. Locate the key way on the truck, align the slot an slowly push the pulley on as far as it will go. Be sure to hold the pulley straight so you do not damage the oil seal in the engine.

Using the bolt that ASP provided, tighten the pulley on about ½ way. Then REMOVE that center bolt and use your OEM bolt and tighten. ( You may choose to replace the crank bolt, $5.00 From ford, But it is not necessary) This will draw the pulley on to the crank. Install a Gates K060845 belt. While holding the crank pulley the same way you did to loosen the bolt, Tighten it to 85 Ft lbs. I tightened mine to 95 ft lbs.

Now your ready to install the fan and shroud. Tighten the fan clutch hand tight. Tighten the transmission cooling line if removed. Be careful not to over tighten this. Install the lower splash shield, air intake , 4.0 cover and connect the battery.

Start the truck and enjoy. !!!!!

This Project is designed to help you install the pulley, and is not a technical report. There may be errors and every truck may be slightly different. The author is in no way liable if you cause damage to your truck following these instructions.

I have this pulley on my truck for a week now and over 300 miles without any problems.

ENJOY!!!!!