Aluminum Underdrive Pulley Kits
1996-Current 4.6L/5.4L
6 and 8 Rib Auto/Truck
Part # 1555, 1559, 15550
INS-053
Step 1 Disconnect the battery.
Step 2 Loosen alternator nut (this will require an air impact gun). Do not remove.
Step 3 Loosen the four (4) bolts for the water pump pulley. Do not remove.
Step 4 On truck models, the engine fan is threaded onto the water pump shaft end–it must be unthreaded in a normal
CCW direction usinf 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 two (2) of the water pump 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 attempting this removal.
Step 5 Remove center bolt and washer from the factory pulley/dampener.
Step 6 Remove alternator pulley and water pump pulley.
Step 7 Use a three (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 crankshaft.
Step 8 Install hub of factory harmonic balancer pulley in counter bore of new pulley. Align threaded hole in each pulley
together. The keyway location is not important.
Step 9 Install and hand tighten three (3) 1/4 x 1-1/4" bolts. The factory pulley does not completely sit into the underdrive
at this point. Carefully tighten the three (3) bolts equally in small increments to draw the two (2) pulleys together.
Remove the three (3) 1/4" bolts.
Step 10 Apply a hi-temp silicon sealer to the two (2) pulley assembly keyway. Place pulley assembly onto the crankshaft.
(Align pulley keyway with crankshaft key.)
Step 11 Reinstall the three (3) 1/4" hex bolts using locktite #242 and tighten to 10-12 ft/lbs.
Step 12 Align the keyway on the two (2) pulley assembly with the keyway on the crankshaft and slide it on to the
crankshaft.
HINT
Place the two (2) pulley assembly in HOT water
for about 15-20 minutes prior to installation
Step 13 Attach the two (2) pulley assembly to the crankshaft using the new
12mm bolt provided and the original crank bolt washer.
Use locktite #242 or equivalent on the bolt and torque to 60 ft/lbs.
Step 14 Install the new water pump pulley using the original hardware.
Use locktite #242 or equivalent.
Step 15 On truck models, reverse Step 4 in order to reattach the fan.
Step 16 Install the alternator pulley with the appropriate one of two supplied
spacers to allow proper belt alignment and attach with original hardware.
Step 17 Reinstall the belt. Consult a shop manual for proper procedure.
NOTE
Inspect belt prior to reinstalling. If evidence
of wear exists, replace it with a new belt.
Step 18 Tighten alternator nut using an air impact gun.
Step 19 T
ighten water pump bolts evenly.
Step 20 Reconnect batter
y
.
Step 21 Start engine and check belt for proper alignment.
INSTALLATION INSTRUCTIONS
www.BBKPERFORMANCE.com
IMPORTANT—All appropriate safety equipment (e.i., gloves, tools) must be used during the installation of this product(s).
BBK Performance, Inc. accepts no responsibility for injuries resulting in the installation of any product(s).
STOCK (OEM)
PULLEY/BALANCER
BBK ALUMINUM
PULLEY
CRANKSHAFT
HUB
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