Ford F-150 (2004-2008) :: Top Right Idler Pulley Bolt Broken


Sep 9, 2017

Doing some charity work on a '04 5.4. Noticed top right idler pulley was sitting on a 45* angle, figured it was shot and decided to replace it. The bolt broke. Borrowed an Easy Out. Short version, I have a very messed up bolt hole. Tried drilling and tapping but couldn't get it to bite and was scared to go bigger. I don't know if the threaded part pulley actually mounts can be replaced and if so how to go about it. Not sure how much deeper I can drill if it can't be replaced? At a standstill.

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I noticed my engine whine more than it usual since the last few days. So, I took it to the dealership and have them check. They said that it is the idler pulley going bad. Just want to see some info on diagnosis.

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So from reading around a lot, it seems like the chirping is from the belt tensioner or idler pulley. That said, I've not been able to find anything definitive. I tried to do the water bottle squirt test (from Gates' youtube video) and either I did it wrong or the chirp did not go away implying the issue is not the belt. While I was looking in, I could see the tensioner shaking some.

If my tensioner should not be moving, do I just need the pulley or the pulley and the mount?

- Pulley [URL] ....
- Pulley and mount [URL] ....

Also, if the above items will fix the chirp, which brand would be best?

2007 RX 350, 113K.

Chirping gets worse as it heats up. Seems to happen independent of ambient temperature. Purchased a year ago so unsure of the history of part changes.

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I only have a tensioner on the left side of the alternator. The one on the right is missing. There appears to be a threaded hole where a pulley should go. Since I bought this used, I thought the previous owner took it off.

I used the bolt from the old tensioner pulley I replaced for the hardware and put a new pulley on.

I also looked at other V10s on used car lots and none of them had the pulley to the right of the alternator. Should there be one there?

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My question is: Should I take the risk and have it driven here before the belt change (I did look at it while I was out there and it's already cracking pretty good), or should I go ahead and have someone get the belt done at a shop? It's less the belt that concerns me I think, and more the pulley, even though it's just started squeaking in the last 1000 mile.

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