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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/3rd-gen-powertrain/2506287-pulley-option-belt-changes-old-style-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/3rd-gen-powertrain/2506287-pulley-option-belt-changes-old-style-fluidampr-2.html#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-present-cummins-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...
 

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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 wasn’t 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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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 dissappered 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.
 

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Discussion Starter #5
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 wasn’t 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.
 

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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.


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/12v-24v-and-24v-common-rail/all-inclusive-serpentine-systems/

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Discussion Starter #7
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/12v-24v-and-24v-common-rail/all-inclusive-serpentine-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.
 

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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.
 

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Hey folks, If a smller pulley somewhere would work so would a longer belt.
 

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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 wasn’t 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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You're better off and it's cheaper to take the pulley's off and just buy the shorter belt for $20.00 The belt is 4' shorter. That's four feet in case you thought it was a typo. I'm still trying to talk someone else into trying it so every one doesn't think I'm a nut job.
 

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Think you would have had the opposite effect if you were running a fan. It would be spinning the fan faster, great for a bit more air at lower speeds but would then to add load.
Cheers Steve
 

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That wasnt the end of it... took a file to the replacement to get it to fit. minor issue but still...




Look how old that belt looks already...

 

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Discussion Starter #17
Think you would have had the opposite effect if you were running a fan. It would be spinning the fan faster, great for a bit more air at lower speeds but would then to add load.
Cheers Steve
That bottom pulley, the fan pulley is smaller in diameter and would drive a manual fan faster so mpg would most likely suffer. I think it would be better at cooling though. In my case it appears to be a bump in mpg. Adding the 2nd pulley, there is definitely a change in throttle response and less drag on the motor. Driving around town its clear when hitting hills in higher gears, downshifts are required less frequently.
 

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Discussion Starter #18
You're better off and it's cheaper to take the pulley's off and just buy the shorter belt for $20.00 The belt is 4' shorter. That's four feet in case you thought it was a typo. I'm still trying to talk someone else into trying it so every one doesn't think I'm a nut job.
too late... :grin2: and welcome to the club :grin2:
 

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Discussion Starter #19
You're better off and it's cheaper to take the pulley's off and just buy the shorter belt for $20.00 The belt is 4' shorter. That's four feet in case you thought it was a typo. I'm still trying to talk someone else into trying it so every one doesn't think I'm a nut job.
too late... :grin2: and welcome to the club :grin2:


regardless of what anyone thinks... I am happy with a 20.x mpg DGAS tank doing 75-85... I am also considering the e-pump at some point.
 

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Not a typical 200 miles but not uncommon... ~75% of the drive was at 55 or above, the rest between 35~45.

 
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