Crankshaft Pulley: Removal

CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
Remove the valve cover. For additional information, refer to VALVE COVER in this article.

CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
- The hole in the crankshaft pulley should be in the 6 o'clock position.
  
  Fig 1: Turning Crankshaft Clockwise
  Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig 2: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Install the special tool in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 3: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the crankshaft pulley removal and installation.

Fig 4: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Install the special tool.
Assemble the special tools using 4 hardened washers in the locations shown.

Fig 5: Assembling Special Tools (205-072-02 And 205-126) And Hardened Washers
Courtesy of FORD MOTOR CO.

CAUTION: The crankshaft must remain in the TDC position during removal of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the special tool and the bolt should be removed using an air impact wrench (1/2-in drive minimum).

CAUTION: If the crankshaft sprocket diamond washer comes off with the crankshaft pulley, it must be installed back onto the crankshaft.

Using the special tools and an air impact wrench, remove the crankshaft pulley.
- Remove and discard the crankshaft pulley bolt and washer.
- Remove the crankshaft pulley.
  
  Fig 6: Using Special Tools Assembly (205-072-02/205-126) And Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.