idler pulley broke part of timing cover

jonathan2000gt

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so the other day my idler pulley snapped a piece of timing cover, i want to know if theres a way to bypass or fix this issue just finally got a swap done and was so ready to get this thing rolling now this please of anyone knows what to do let me know asap?hash=b69bb7444e9660ed1786da3badf1c91d.jpg
 

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96blak54

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Well that sux!!

Oh geez, i dont know. Simplest solution would be to replace the front cover. If you dont use the a/c pump, you can buy a 6 rib pulley at the parts house to replace the stationary idler to the left of the water pump and use a shorter belt.
 

96blak54

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Wait....this ^ may only work out on a 5.4l. I did it to mine and its a 5.4l.
Maybe someone will chime in with some help
 

lwarrior1016

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Unfortunately, you can’t have a/c until that cover gets swapped. To get you on the road now, get a grooved pulley from something like a 2005 town car and swap it to your tensioner. Then get a shorter belt.
 

lwarrior1016

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hey what serpentine belt did u end up using for this might do this until i have time to swap out the cover?
Full disclosure, that’s not my picture lol. What I typically do is get a piece or rope and route it like the belt, then move the tensioner like half way through it’s travel and pull the rope right. Then take it off and measure it (you could also use a seamstress tape measure). Then just buy that length belt from the parts store.
 

RAU03MACH

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just a question is that a 2 valve
if so i will be changing mine over to a 4 valve and i wont need the 2v cover
but just keep in mind it will be a bit, i still need to get a few things together before i start
would you need one asap
 
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jonathan2000gt

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Full disclosure, that’s not my picture lol. What I typically do is get a piece or rope and route it like the belt, then move the tensioner like half way through it’s travel and pull the rope right. Then take it off and measure it (you could also use a seamstress tape measure). Then just buy that length belt from the parts store.
how the hell he even get the belt like that around the tensioner
 
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jonathan2000gt

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Full disclosure, that’s not my picture lol. What I typically do is get a piece or rope and route it like the belt, then move the tensioner like half way through it’s travel and pull the rope right. Then take it off and measure it (you could also use a seamstress tape measure). Then just buy that length belt from the parts store.
cant figure out how the guy got the belt around the tensioner like that any thoughts?
 

97CobraNoob

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Reviving an older thread here. I have the exact same issue on my 97 Cobra 4v timing chain cover. The idler pulley mounting point broke as I was removing the pulley to be replaced. Literally looks like the exact image by the OP. The cast covers seem to be weakening over time in this area. My question is are there any aftermarket timing covers that are billet?
 

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