I have just received a replacement idler pulley from Rockauto for my 2.5L duratec powered Mondeo - but the pulley is the wrong size - the part I received is about 90mm (3 1/2") diameter and smooth whereas my engine has a pulley of about 60mm (2 3/8") and it is ribbed to accept the serpentine belt.

Here is a photo of my pulley:
http://i43.photobucket.com/albums/e367/kiwiford/IMG_3967x.jpg

My question is - what size idler pulley do members have on their duratecs?? Have I been sent the wrong part or do the USA duratecs have a different accessory belt/pulley arrangement to the european duratecs? If someone could photograph theirs that would be most helpful!

Thanks

Will this help?
http://www.contour.org/php/showpic.php?img=/gallery/duratec/durright.jpg

Yes that definitely does help - I measured my power steer pulley at 150mm (6 inches) because its easy to measure! and then applied a ratio of a printed version of your photo to see what dimension the idler is - and sure enough I calculate the idler pulley at 61mm give or take.

It also appears that the pulley would have to be ribbed to run on the inside of the serpentine belt..

Which all leads me to believe that the parts people may have it wrong. If you have time could you possibly give me an opinion on that - check rockauto.com - I use the 1996 Contour LX 2.5L - and under accessory belt it quotes 3 parts - Four Seasons #45975 (which I got), Delco #38001 and Delco #1520679 - now the 2 with 'more info' show photos which look like the one I have received
http://i43.photobucket.com/albums/e367/kiwiford/IMG_3969x.jpg
I also checked on autozone.com - they show a similar part AC Parts 45975 which is the same as at rockauto. I'd appreciate a steer in the right direction to get the correct part from a USA supplier!!

Many thanks

Malcolm

I recently ordered a new idler pulley from Ford as the bearing was shot in mine. When the parts came in and they told me the $35 price I said "forget it"! Unfortunately, the pulley is plastic and the $8 bearing cannot be removed. So I grabbed some 2.5" OD AL bar and fabricated one on the lathe. The correct OD to the top of the rib is 2.295".

I suspect that what the dealer has supplied you is the belt tensioner idler pulley. The bearings in these CAN be replaced.

For interests sake, the early Cougars used a steel pulley which is significantly heavier than the plastic Contour part (bearing is the same). Later Cougars and 3.0's do not have an idler pulley at all.

Sorry about the use of Imperial measure, but that's what I work with. (2.54 cm. = 1")

Trust this helps.

Thanks for that - through Ford here in New Zealand this part is NZD 100 or about Canadian 50! Yes that definitely is the part - Rockauto must have sent me something for another car not of this planet. The tensioner pulley I make about 71mm or 2.8" so the pulley I received at 90mm just isn't right for idler or tensioner pulley. Strange too, as on the rockauto.com site and the autozone site, they both quote the part number I received and have a picture matching it! Anyway I'll keep looking and may have to stump up the funds at Ford, ouch
Cheers,