Ford Explorer: Generator and Regulator / Removal and Installation - Generator Pulley

Removal

1.   WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

   Follow the health and safety precautions.
   Refer to: Health and Safety Precautions (100-00 General Information, Description and Operation).
   

1. Remove the generator.
   Refer to: Generator - 3.0L EcoBoost (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 2.3L EcoBoost (201kW/273PS) (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 3.0L EcoBoost (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 3.3L Duratec-V6 (414-02 Generator and Regulator, Removal and Installation).
   

1. Using a small screwdriver or similar tool, insert the tool through the rubber button on the center of the pulley cap and pry off the cap. Discard the cap. A new cap must be installed if the clutch is ok.
   

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   NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

   NOTE: The shaft and rotor will turn during removal.

   Using a 17 mm hex tool and an impact gun, remove the clutch pulley. A couple of short bursts with the impact gun will remove the clutch pulley.
   

Installation

1. Install the pulley and hand start.
   

1. NOTICE: Do not insert anything into the fins of the generator to prevent the rotor inside the generator from turning. Inserting items into the generator could result in damage to the generator.

   NOTE: The shaft and rotor will turn during installation.

   While holding the outer diameter of the clutch pulley, torque the clutch pulley using a 17 mm hex tool, 75 Nm torque stick and an impact gun for 3-4 seconds. This makes sure the proper torque has been applied.
   Torque: 55 lb.ft (75 Nm)

1. Install a new cap onto the pulley with the rubber button facing inwards.
   

1. Install the generator.
   Refer to: Generator - 3.0L EcoBoost (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 2.3L EcoBoost (201kW/273PS) (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 3.0L EcoBoost (414-02 Generator and Regulator, Removal and Installation).
   Refer to: Generator - 3.3L Duratec-V6 (414-02 Generator and Regulator, Removal and Installation).