Lightweight Pulleys - Dodge Cummins Diesel Forum
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post #1 of 87 (permalink) Old 08-16-2019, 11:13 AM Thread Starter
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Lightweight Pulleys

OK guys, gotta share this CF with you... I sit back and laugh at it even though I was pretty frustrated...

No WAIT... STOP... Go get a beer or popcorn before proceeding...

I have the original Fluidampr on my crank which requires its removal to be able to swap the belt every 100k. OK fine, went thru that 1x and what a PITA it was. Along comes this thread

https://www.cumminsforum.com/forum/3...fluidampr.html

and the option to swap the fan pulley for one with a smaller diameter. OK cool, I'm in.. so I get it, go to do the install, bolt it up and it wobbles... WTF! So I pull it off and put it on a flat surface and sure enough the mounting surface is warped. So I get a new one in hand (Thanks PDP!!!) verify its flat and go to do the install. This time however I yank off the fan pulley bracket to have a nice close look at it and discover that the pulley was not sitting flush as indicated in this post...

https://www.cumminsforum.com/forum/3...l#post29054313

After some grinding and test fitting, its good to go. Immediately I notice a change in throttle response. Thinking eh its a placebo effect I shrug it off and motor on. Well come to find out that after driving it a bit, no it is not a placebo effect and indeed there is a change in throttle response. Similar to what I saw with the AL driveshaft but no where close to the same level. Motivated by what I see I order up a Beans Machine Idler pulley

https://bdpshop.com/bean-machine-03-...-idler-pulley/

It arrives and the excitement to pop it in there is high. Sooo, I go to do the install, pull the old pulley off and I find a washer behind the bolt head. Not thinking it thru i drop the new pulley on there and give it a spin... and it goes no where... Huh?!



Off it comes and I investigate. I found there should have been a spacer behind the bolt head to align the original pulley so the belt sits correctly on it. I also noticed that the belt might not line up correctly from pulley to pulley. Phone rings and FedEx says my address is wrong for a shipment... huh? Confirm the address is correct and it was from Beans so I said deliver it. So next I button it all back up, check belt alignment and confirm its good to go to work the next day. Doing some investigating I found that there is a bushing/spacer that was needed on the front side of the pulley. Some quick Googling and viola, here is the part I think I need...



So I get it ordered and it will be at the local parts shop the next day... Cool! Excitement continues.

The next day at work I get a delivery from Beans...and this is what was in there...





Ah, so I was right, there was a miss-alignment. cool! Now I have the front and rear spacers in hand and the excitement builds once again.






Four Seasons, Napa P/Ns



so I go ahead and tear it all apart again (thankfully its a 10 min swap, max) and guess what I now discover (shoulda seen this coming hahaha)



Yup, the bolt is too long. *#&%$#@....$#%^##%@@...

Sigh.... OK I will tear it apart yet again, back to stock and go find the bolt. So I slap in my new spacer and ditch the washer, put it all back together and take a nice break. My enthusiasm is deteriorating...

After a good break I jump in the truck and go to the best source for the bolt that is open and yet again, tear it down so I can walk in with the bolt for fitment. As I'm walking into the store I discover the spacer has now welded itself to the bolt AND will not come off... *#&%$#@....$#%^##%@@...



I locate the bolt inside the store and go to pay and there is a line... sigh... there was no one in there when I walked in and now a line, sigh, "ok, relax and wait, be patient..." how long can it take to get out. 15 minutes... with 2 cashiers and 1 person in front of me. Once back at the truck I give it one final shot to yank off the spacer and nope, not budging. OK *#&%$#@ it, I have ideas, get to work tomorrow and toss it in the freezer, that should break it free... then I started thinking, it was a $4 part, go buy another. Oh wait, parts store #1 said they only had one in stock... so I will call napa and see if they have it. Fortunately they do so I grab the P/N and will be heading over @ lunch to pick one up.

fun in the sun on a simple pulley install... Anyways, hope some found this amusing, I did thinking back on it.


shorter bolt specs M10 1.5 pitch 60mm



Comparison pics:










I will add some impressions of the 2nd install performance later along with a pic of the weight of the OEM pulley. for anyone who cares about this stuff...


AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #2 of 87 (permalink) Old 08-16-2019, 11:29 AM Thread Starter
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First pulley install pics










FWIW, last tank, 100% eco drive = 22.5 mpg

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #3 of 87 (permalink) Old 08-17-2019, 09:23 PM
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I was just looking at them pulleys and started doing a little research some guys claimed that they freed up some HP because of the lighter parts moving , some others said that wasnít worthy cause the aluminum parts wore out and ended installing back their old pulleys . My opinion they look great but I will hate to waste my time and money just my 2 cents


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post #4 of 87 (permalink) Old 08-17-2019, 11:44 PM Thread Starter
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Feedback: Got it installed last night & immediately noticed the bump in throttle response had gone bye bye. I thought this was due to the bearing being tight and it would loosen up. Today was race day in Portland, 2 tracks, 75~85 most of the way, stop & go traffic a few times in Portland. The drag I thought the bearing had dissipated and throttle response returned and then some. Seems like it took about 160~180 miles for it to happen with a couple of long stops at the 2 tracks.

Pretty happy with it and I will go and get the power steering pump pulley when I need to swap the pump. MPG for the tank came in at 20.2 mpg, never had it that high driving the way I did so needless to say, pleased with it. FWIW, I rebuilt and installed the 2nd air dam which I know helps with high speed mpg. Last time I was doing 80~85 in Idaho back at Memorial day week the best I did was an 18.5 mpg. Tank full & I am out for 10 days starting Wednesday so it will be a while before I can get back to it.

Is it worth it? Yes IMO it is. throttle response alone is worth it. I have a tune waiting to go in and plan to look at the base log to see if the timing needs to change at all for the bottom end boost. As it sits, I dont think so, seems fine as is.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #5 of 87 (permalink) Old 08-17-2019, 11:45 PM Thread Starter
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Quote:
Originally Posted by Kirby5.9cr View Post
I was just looking at them pulleys and started doing a little research some guys claimed that they freed up some HP because of the lighter parts moving , some others said that wasnít worthy cause the aluminum parts wore out and ended installing back their old pulleys . My opinion they look great but I will hate to waste my time and money just my 2 cents


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I guess I will be putting this to the test, 35k mi a year or so... will see how long it takes.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #6 of 87 (permalink) Old 08-17-2019, 11:53 PM
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Lightweight Pulleys

Quote:
Originally Posted by steve05ram360 View Post
I guess I will be putting this to the test, 35k mi a year or so... will see how long it takes.


Like I said I almost bought them last week but after what I read I backed off, I think they look great and in my head they make sense . Report back later on I will probably end up buying them too if you get good results with them

I look at beans diesel and this other website

https://www.cvfracing.com/cummins/12...ntine-systems/

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post #7 of 87 (permalink) Old 08-18-2019, 12:05 AM Thread Starter
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Quote:
Originally Posted by Kirby5.9cr View Post
Like I said I almost bought them last week but after what I read I backed off, I think they look great and in my head they make sense . Report back later on I will probably end up buying them too if you get good results with them

I look at beans diesel and this other website

https://www.cvfracing.com/cummins/12...ntine-systems/

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do you have any links to what you read on them wearing out? I run 30~40k/yr, I would expect to not have to change them again unless they break.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #8 of 87 (permalink) Old 08-18-2019, 12:17 AM Thread Starter
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here is a link...

https://www.svtperformance.com/threa.../#post-7765193

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #9 of 87 (permalink) Old 08-18-2019, 01:36 AM
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Good stuff, made me...parts store shenanigan's! laugh...sounds so familiar

03 QCLB- 19 to 25 mpg with electric parts, and engine mods....
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post #10 of 87 (permalink) Old 08-18-2019, 02:06 AM Thread Starter
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yeah it was frustrating... and i did not post a pic of how the replacement spacer failed to fit the bolt. had to file it a bit on the center bore. i took a pic at the time and will add it tomorrow... icing on the cake.

should also add, that nice green belt, looks pretty old now...

the shocker is the mpg based on past trips along with how i drove it today... i will have to go back and look at past fuel receipts but i recall upper 18s for the same trip & speeds.

AFE PG7 drop in filter, AFE Torque Tube, HTT 2.5 turbo, AFE e-mani, ATS Arc Flo, 50HP DDP , 422k, HPTuners, G56, 25.065 mpg, mpg threads ->https://www.cumminsforum.com/forum/3...l#post23312562
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post #11 of 87 (permalink) Old 08-18-2019, 03:53 AM
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Hey folks, If a smller pulley somewhere would work so would a longer belt.

99 2500, Quad cab, 4x4 47RE, BD pressure lock on it, small BD 90/140 chip on the VP 44 connection plug, 17" 3rd gen wheels. 3.55 diffs. Ruenell front bumper and warn winch, Rancho adj shocks. 663k miles.
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post #12 of 87 (permalink) Old 08-18-2019, 11:04 AM
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I have one of those fan pully's if anyone wants one.

03 QCLB- 19 to 25 mpg with electric parts, and engine mods....
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