Owners manual

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Aluminum Under-drive

Pulley Kit

Part # 1555: 1996-01 Ford Mustang GT/Cobra

Part # 1559: 2001-04 Ford Mustang GT

Part # 15550: 1997-04 Ford F-Series/Expedition 4.6L/5.4L

INS-053

NOTE: 15550 fits 6 and 8-Rib applications. 6-rib applications will simply use the outer 6 ribs of the new pulleys.

IMPORTANT!!! See page 4 for Water Pump Identification!!!

Special Tools

Required:

•

Impact Gun

•

3 Prong Harmonic

Dampener Puller

Install Time:

Approximately

1 Hour 30 Mins

Difficulty:

3 out of 5

STEP 1

STEP 4

• Disconnect the negative battery terminal.

STEP 2

• Loosen the alternator nut. (This will require an

air impact gun) Do not remove!!!

Loosen the (4) bolts for the water pump pulley.

Do not remove!!!

• Remove Serpentine Belt

• Remove the center bolt and washer from the

factory pulley/dampener. Remove the alternator

pulley and water pump pulley. Use a 3 prong

harmonic dampener puller to remove the factory

pulley/balancer. HINT: Hold the pulley with

one hand when removing it. This will keep

the pulley/dampener from falling to the

ground when it clears the end of the crank

shaft.

STEP 3

• On truck models, the engine fan is threaded

onto the water pump shaft end- it must be

unthreaded in a normal counter clock-wise

direction using a large wrench on the hex-nut

portion of the fan clutch where it meets the

water pump pulley. Additionally you will need a

tool which attaches across 2 of the water pulley

bolts and allows you to put resistance in the

direction of the fan nut while breaking the nut

free- otherwise the water pump will simply rotate

while trying to remove.

Summary of content (4 pages)

PAGE 1
Aluminum Under-drive Pulley Kit Part # 1555: 1996-01 Ford Mustang GT/Cobra Part # 1559: 2001-04 Ford Mustang GT Part # 15550: 1997-04 Ford F-Series/Expedition 4.6L/5.4L Special Tools Required: • • Impact Gun 3 Prong Harmonic Dampener Puller Install Time: Approximately 1 Hour 30 Mins Difficulty: 3 out of 5 NOTE: 15550 fits 6 and 8-Rib applications. 6-rib applications will simply use the outer 6 ribs of the new pulleys.
PAGE 2
Aluminum Under-drive Pulley Kit Part # 1555: 1996-01 Ford Mustang GT/Cobra Part # 1559: 2001-04 Ford Mustang GT Part # 15550: 1997-04 Ford F-Series/Expedition 4.6L/5.4L STEP 5 • Install the hub of the factory harmonic balancer pulley into the counter bore of the BBK Pulley. Align the threaded hole in each pulley together. Install and hand tighten the (3) ¼ x 1-1/4” bolts. The factory pulley does not completely sit into the under-drive at this point.
PAGE 3
Aluminum Under-drive Pulley Kit Part # 1555: 1996-01 Ford Mustang GT/Cobra Part # 1559: 2001-04 Ford Mustang GT Part # 15550: 1997-04 Ford F-Series/Expedition 4.6L/5.4L STEP 8 STEP 10 • • Attach the pulley assembly to the crankshaft using the new bolt provided and the original crank bolt washer. Use locktite or equivalent on the bolt and torque to 60 ft/lbs. Install the new water pump pulley using the original hardware. Also use locktite.
PAGE 4
Aluminum Under-drive Pulley Kit Part # 1555: 1996-01 Ford Mustang GT/Cobra Part # 1559: 2001-04 Ford Mustang GT Part # 15550: 1997-04 Ford F-Series/Expedition 4.6L/5.4L Identification Guide for 4.6L Water Pump Pulleys Visually identify which water pump pulley you have before installing regardless of model year. The early water pump pulley had a convex or “bowed-out” face and the pulley on the later water pump has a concave or “pressed-in face”. There is no exact changeover date for the pump and pulley.