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Alternator clutch pulley mod?

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25K views 19 replies 8 participants last post by  Jurca  
#1 · (Edited by Moderator)
Whilst looking around about tensioners prior to replacing mine for the second time in 40k, I saw mention of ADP's helping on transits and Jag X Types - basically a one way clutch fitted to the alternator to stop "belt slap" and excessive movement on the tensioner.

i found an article on here from a few years back about a guy from Hungary who had converted his and cleared the noise significantly from the pulleys - has anyone over here done this?
 
#2 ·
  • I have removed the AC pump and fitted a shortend serpentine belt, (11kg weight saving/ less rotating mass) The belt is unnessesarily long and complex but at least it has 2 less pulleys to turn.
  • If you can live without the AC there is a significant performance/ economy advantage, the crankshaft/ belt only has to drive the alternator (with the AC pump gone), reducing the load and potentially increasing the longeviety? of the belt.
  • I got rid of mine because -
  • I hardly used my AC
  • - 2 / 3 months of summer - 9 / 10 months of winter (or not hot enough to use AC)
  • it never worked that well anyway
  • it needed a recharge
  • when i put the AC on i knew it impacted the economy badly
  • latterly i was modifying my car for serious performance and someone had done it to a mk1 or 2 petrol and said it made a big difference
  • i don't have to worry about the AC not working right, recharging it / wasting power/ fuel or adding unnessesary weight - ever again
    Image
  • PS not shure about the "rattling sound", lets just say i can't hear it above the racket of the unsound deadend engine under the vented bonnet, the induction roar of the 80mm inlet or the noise from the straight through pipe
  • i hope this is useful to you
 
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#3 ·
hey mk3_turbo, thanks for the reply. I want to keep the AC compressor really, as it's a daily driver for 75 miles per day - including being stuck in the crap traffic that is the M62 every day!

I thought as they fit these to the TDCi transits, that there must be one that would fit the Mondeo TDCi as well? i'm surprised that they didn't fit one to be honest, given that most modern serpentine belt systems with damped pulleys and flywheels have them....
 
#4 ·
  • Well i know someone with a Titanium X 2.2, the "rattling" at tickover is probably the worst and most annoying aspect of the car...
  • The Jaguar X type (some models anyway) & mk3 Mondeo have many parts in common (some might say its the same car, "badge engineered")
  • If this device is fitted on to an X type alternator, would it be possible to fit it straight on to a Mondeo mk3 alternator?
  • Other parts may have to be changed, possibly the alternator, the pulleys, the serpentine belt?
  • It may be worth persuing this, and find out what it takes to do, im shure others would be very interested.
  • A good starting point would be to find what parts (of the belt/ pulleys etc) the X type/ mk3 have in common?
  • I wonder why Ford did not fit one in the 1st place?
 
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S
#5 ·
the reason why you dont read about this being done to a mk three is its not really necessary because there are two idler pulleys and the belt normally on a mk three dosent slap too much atall . it has a spring loaded tensioner also which applies alternating tension if the the tensioner on your mondeo mark three went twice in 40 k it is most unusual and this is not a frequent fault on these motors . and on the transit the belt is longer and it dosent have the guide pulleys afaik . but you can trawl back over the archives here and you wil find very few if any problems like you mention in fact it is one of the more reliable parts of the engine in my opinion . soo im surprized you had to replace a tensioner and belt twice in 40 k . unless the mech putting the replacement tensioner in put in inferior stuff of bodged the job it shuld really only be a once in the lifetime of an engine job ..s
 
#7 ·
Hate to disagree with you there salta, but I think shamus is right - it's immensely common for these things to go - when Ford replaced the pulleys and tensioner under warranty they were being done at 20,30,40k from new, and a lot of people tend to start hearing the rattle come back after about 20-30k. As for parts, when i do a job i tend to be a pedantic bugger about things and replace everything. full Gates belt, tensioner and pulley set (i suspect OEM Ford, as they had all the ford badges and part numbers on), and a genuine Ford later revision crankshaft pulley.

As for tensioners etc - the transit videos i have seen show a tensioner on those as well - although admittedly the tensioner looks more like the one fitted to the power steering belt on the Mondy TDCi. If you look at the belt on my TDCi for example, although the belt slap is nowhere near as bad as the videos of transit belts, it still has some 'slap', particularly because of the low idle speed on the TDCi compared to normal.My theory here is that because of the low idle speed, the engine tickover is a bit uneven - therefore fitting an alternator clutch could prolong the life of the tensioners and maybe even the crank pulley?
 
#8 · (Edited by Moderator)
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D
#10 ·
already replaced i for one with bearing inside,
it came i thing from the 1.3 multijet motor(obviously i put one new) the brand was INA a good brand for bearings...

big difference in idle! I recommend the change, it cost around 40€ plus one or two hours for change it

for sure the the tensioner and the "big"(don't remember the name in english) pulley will last longer...
 
#11 ·
ok well i've done some digging around online - it appears that the alternator for the petrol models comes in both standard and clutched pulley - the part number for the clutched model is the same as the part number for the diesel (although minus the clutched pulley). The connections and mountings all look the same as well - hust wondering if the power ratings etc might be different as diesels used to require more power?
 
#14 · (Edited by Moderator)
Well according to Eurcarparts site, the petrol and diesel have different sized mounting holes, and different wiring connectors?

I can't understand why ford didn't fit them in the first place - they did it on some models of petrol car, and there seems to be an awful lot less Petrolheads reporting failing tensioners/crankshaft pulleys than dervheads....
 
#15 ·
Ok well i reckon this is something i am going to do. Got to say a big thanks to relhist who lurks round here from the Hungarian Forums - his help has been invaluable!

From my chats with him, it is a common mod over in Hungary, over 100 TDCi's have been done, with only about 4 have had failures, and they have been due to people not renewing everything at once....so got to be worth a try!

Basically, it involves cutting the raised ring off the alternator housing round the spindle (pretty simple job); and then fitting the clutch pulley from a mondeo petrol (Zen part no 5429)....that's it!

sounds like £30 well spent on the pulley....and a nice sunday afternoon job
Image
i'll do this soon and post it up in the Wiki for anyone interested - need to share the knowledge!

This is the before and after pics to show you what needs changing - you can swap regulators around instead (or even swap the front housing of the alternators round if you feel like a refurb of the alternator at the same time!), but this is the simplest way of doing it.....

BEFORE MOD

AFTER MOD
 

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#19 ·
bigi said:
Ok well i reckon this is something i am going to do. Got to say a big thanks to relhist who lurks round here from the Hungarian Forums - his help has been invaluable!

From my chats with him, it is a common mod over in Hungary, over 100 TDCi's have been done, with only about 4 have had failures, and they have been due to people not renewing everything at once....so got to be worth a try!

Basically, it involves cutting the raised ring off the alternator housing round the spindle (pretty simple job); and then fitting the clutch pulley from a mondeo petrol (Zen part no 5429)....that's it!

sounds like £30 well spent on the pulley....and a nice sunday afternoon job
Image
i'll do this soon and post it up in the Wiki for anyone interested - need to share the knowledge!

This is the before and after pics to show you what needs changing - you can swap regulators around instead (or even swap the front housing of the alternators round if you feel like a refurb of the alternator at the same time!), but this is the simplest way of doing it.....
Click to expand...
Image

I certainly recommend doing this mod.
I don't know what salta talks about these parts being reliable. In-town usage combined with uneven idle and badly designed system brings back the rattle and belt slapping under 3k miles.
Image

The belt is too long, the 750 idle is too low and can be uneven and you have a PCM controlled 90amp alternator to deal with.
Image


Credit for the photos goes to my forum-mate, Alf.
Image
 
#17 ·
well it certainly sounds like it's worth doing - relhist was saying that at 750rpm idle you can constantly hear the clutch kicking in due to the uneven idle of the TDCi engine. he reckons these pulley last around 40k, but at the end of the day i'd rather pay £30 for a pulley every 12-18 months than £200 on pulleys and ternsioners!
Image
 
J
#20 ·
Since this topic hasn't been updated for so long, I presume that this problem has been solved, but I still think that I should mention what I did. (at least save someone some time from digging around for the information)

When my crank pulley went south, I searched all over the place to find a way to replace the original alternator pulley with a clutched version at the same time, and after finding out that non of the previously mentioned pulleys can be used, my mechanic found out that there is a replacement part, that usually goes on transit vans.

The part is INA 535022310 and you just swap the pulleys without the need to grind or modify anything (just some tiny leftovers from casting).

I hope I made it easier for someone to make this mod.
 
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