96 F250 7.3 Idler Pulley - Diesel Forum - TheDieselStop.com
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Power Strokes 1994-1997 General Technical discussion of topics related to vehicles powered by the Power Stroke engine in 1994 through 1997 models.

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Old 09-20-2005, 11:08 PM   #1 (permalink)
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96 F250 7.3 Idler Pulley

OK i have a friend that needs me to replace her Idler Pulley....Is there anything i should need to know about replacing it? Any special tools, tricks anything like, or if anyone has a how to on it that would be great too!!!

Thanks for your help Guys
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Old 09-21-2005, 07:17 AM   #2 (permalink)
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Re: 96 F250 7.3 Idler Pulley

Anyone?!?!?
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Old 09-21-2005, 09:54 AM   #3 (permalink)
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Re: 96 F250 7.3 Idler Pulley

T-50 torx on the idlers. The tensioner pulley is 15mm bolt, reverse thread. Keep in mind that the idler below the alternator is grooved, the upper one is smooth. The tensioner pulley is smooth as well. If the tensioner looks out of alignment and pulled forward it is worn and will need replacing.
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Old 09-21-2005, 12:56 PM   #4 (permalink)
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Re: 96 F250 7.3 Idler Pulley

If the idler pully bearing is going, but you still have all of the parts (hasn't flown off yet) you can get a 6203S sealed ball bearing and replace just the bearing, saves a few $. Do em both at once and check all the others, especially the tensioner pully.
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Mine: 91 F250 Reg Cab 4x4 5spd 7.3IDI 4.10LS 145,000 miles. Banks Sidewinder 92 D60 F axle w 97 brakes and Powerlock. Lift: about 4" over stock 250. 33x12.50x16.5 Pro Comp MTs Magnaflow 12" muffler. Sees dirt everyday. Used to haul hay, wood, feed cows, check fence.
Hers: 96F250 CCSB 7.3 PSD 4x4 5spd 3.55 LS 190,000 miles. Puchased 7/03, Looked for a 5spd CCSB for a year!Dana 60 front axle, at stock F350 height (for now) Energy Poly bushings, Bilsteins, 305/70/16 Pro Comps on 16x10 Weld Outbacks, AFE Pro7,TYMAR 3x3.5x4 downpipe,TYMAR 5" straightpipe, gutted EBV, IH Non EBV pedistal,New Alliant AC Injectors,(stage 1)Cal reg kit, SBC Con O clutch, permenent clutch bushing fix, AC mod with a different twist, AMP Powersteps with custom brackets and wiring(one of 2 OBS trucks with them according to AMP) Line of Fire. Sees dirt everyday.
My Company pickup: 86 F250 6.9 C6 320,000 miles Co trucks 5 89 to 94 IDI's, plus about 50 more diesels.
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Old 09-21-2005, 01:06 PM   #5 (permalink)
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Re: 96 F250 7.3 Idler Pulley

When I did mine I used a NAPA replacement due to being on the road on a Sunday afternoon. The lever is slightly longer and the tensioner assembly is a bit longer but it fits. The head of the mounting bolt for the tensioner assembly had to be ground down a bit to clear the belt but once there was 1/16" in there it has been fine for a couple years and somewhere around 40,000 miles.

The longer lever works fine on the factory belt.

I found it easier to get the mounting bolt out of the aluminum bracket it goes into (steel bolt into aluminum and all, you know) by removing the alternator and belt, removing the bracket and use a 1/2" drive impact. Loosen a hit, tighten a hit, loosen a hit etc. until it comes out. It makes the threads in the aluminum bracket stay there.

Don't forget, NeverSeize is your friend on reassembly.

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Old 09-21-2005, 01:13 PM   #6 (permalink)
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Re: 96 F250 7.3 Idler Pulley

Yea, I just checked this out the other day, both Gates and Goodyear both sell a tensioner with a longer lever. I had both in my hand and they are exactly the same just in different boxes. I didn't have any problems with fit up though. I'm a prevention type of guy and I did both idler bearings and the tensioner, now I gotta go back and do the water pump (too much play for comfort) and the A/C bearing (just because it's the only bering not new)
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Mine: 91 F250 Reg Cab 4x4 5spd 7.3IDI 4.10LS 145,000 miles. Banks Sidewinder 92 D60 F axle w 97 brakes and Powerlock. Lift: about 4" over stock 250. 33x12.50x16.5 Pro Comp MTs Magnaflow 12" muffler. Sees dirt everyday. Used to haul hay, wood, feed cows, check fence.
Hers: 96F250 CCSB 7.3 PSD 4x4 5spd 3.55 LS 190,000 miles. Puchased 7/03, Looked for a 5spd CCSB for a year!Dana 60 front axle, at stock F350 height (for now) Energy Poly bushings, Bilsteins, 305/70/16 Pro Comps on 16x10 Weld Outbacks, AFE Pro7,TYMAR 3x3.5x4 downpipe,TYMAR 5" straightpipe, gutted EBV, IH Non EBV pedistal,New Alliant AC Injectors,(stage 1)Cal reg kit, SBC Con O clutch, permenent clutch bushing fix, AC mod with a different twist, AMP Powersteps with custom brackets and wiring(one of 2 OBS trucks with them according to AMP) Line of Fire. Sees dirt everyday.
My Company pickup: 86 F250 6.9 C6 320,000 miles Co trucks 5 89 to 94 IDI's, plus about 50 more diesels.
Diesel Mechanic 34 yrs Maintenece Manager 23 yrs
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