EXTREMELY Squeaky pulley

[wiswind]

Don't bother with trying to solder.
I would try the idea of using another, but equal, ground point.
I do not think that you did any permenant damage with the ground wire not connected.
Your experience is an example of why I think a while before taking something apart.
I find that with each thing removed, another opportunity for something to go wrong is introduced.

I do have pictures of some of my projects posted, and have included pictures of things apart with the intention of being of help to others in working on their vehicles.
I have a picture of the power steering pump replacement process that showes the alternator / power steering pump bracket out of the vehicle.....and putting it back into the vehilce.

I found that removing the alternator was a great help before trying to remove the bracket.....lots less weight to try to work with in trying to get the bracket lined up.

However, as has been pointed out.....there are some differences from year to year, and even mid-year changes....and, not being a mechanic.....just a person fixing my own vehicle, I cannot comment on a situation that is different than my own.
I do not even remember a ground strap, but that might just be that I did not have any problem.
I am in the electrical / electronics field, so I would be extra attentive to making sure that it would be connected.
Bad grounds can cause all sorts of issues.

I have not replaced the tensioner or the tensioner pulley, so I don't have any pictures or advice to give.
You can do a search in this windstar forum room, and see what other's have done.
However, you will want to pay particular attention to posts from people with the same year as you.
1995 is a different layout from 1996......
Then some small changes from year to year through 1998, then 1999 was a major change year.

[searcherrr]

Originally Posted by wiswind

Don't bother with trying to solder.
I find that with each thing removed, another opportunity for something to go wrong is introduced.

LOL - I absolutely 100% agree. LOL I wish my testosterone wouldn't have been guiding my hand that day when I removed the bolt. I had looked at it and thought briefly, but I guess I just didn't understand removing that bolt would mean the alternator would fall downward on the pull of the belt tension. You live you learn. I just hope this thread helps someone in the future.

Originally Posted by wiswind

Bad grounds can cause all sorts of issues.

Yeah, so I've learned. I'm usually really good about that stuff. It is basically just about not wanting to accept that I messed it up. Honestly. Cause now it means having to remove the alternator, machining the bolt hole, etc.. way more trouble than I'd intended on going through to replace a friggin pulley.

Thanks for all your advice and info.

2 Questions
What would be an equal but ground point? I was thinking as long as I'm connected to the alternator to the ground cable thats loose with a match or less gauge wire that I'd be ok. Is that right?

Why wouldn't the solder thing be a good solution? Iffy? I'm just curious.

[wiswind]

Solder, trying to get a good solder connection that will not break later is not going to be easy.......lots of vibration and temperature changes.

If the ground went to the alterator, another alternator bolt would be a good idea.

Another note......it is best to remove the serpentine belt whenever you are doing any work that could end up getting any fluid(s) onto it.
I found that out the hard way.
If the belt has gotten any fluids onto it.....it might be a good idea to buy a replacement belt.
I had gotten power steering fluid onto mine......I cleaned it up really well, but it still lead to the belt failing.
In my case, I was just about to turn into an Autozone parking lot.
They listed several belts, only had 1 in stock.....and only 1 of those.

I have had several of my repair jobs not go well.....happens to all of us.

[searcherrr]

Originally Posted by wiswind

Solder, trying to get a good solder connection that will not break later is not going to be easy.......lots of vibration and temperature changes.

If the ground went to the alterator, another alternator bolt would be a good idea.

Another note......it is best to remove the serpentine belt whenever you are doing any work that could end up getting any fluid(s) onto it.
I found that out the hard way.
If the belt has gotten any fluids onto it.....it might be a good idea to buy a replacement belt.
I had gotten power steering fluid onto mine......I cleaned it up really well, but it still lead to the belt failing.
In my case, I was just about to turn into an Autozone parking lot.
They listed several belts, only had 1 in stock.....and only 1 of those.

I have had several of my repair jobs not go well.....happens to all of us.

Well, before I saw this response I tried to do the soldering and it was exactly the problem you said it would be. It was too melty and even when it dried it was not a very tight bond at all.

I did get some on the belt, but was sure to get it off after a few seconds of dry time and it was cold outside. I then put a shop towel underneath my work so that wouldn't happen again.

SOME GOOD NEWS THOUGH FINALLY ! LOL - THE TOP MOST ALTERNATOR MOUNT BOLT FOR WHATEVER REASON ALLOWED ME TO TURN IT A COUPLE MORE TIMES YESTERDAY AND NOW MY PROBLEM WITH STARTING IS GONE ! I started her up 12 times in a row with no failures and it runs solid now (no grumbling or rough idle anymore as was when the ground was not tight at the alt). So now I'm very happy. Thank you all very much. This forum used to not be so helpful, but I'm glad people have found it and made it something useful/invaluable.

[searcherrr]

It did the "no start" thing again 1 time and then started up right after. I think I'm going to add the extra ground wire and be done with it. Cheerio.

[wiswind]

Other things to check for the intermittent no start, all the electrical connections on the starter.
Some have mentioned no start issues due to corrosion on those connections.

Battery cable connections, including the ground connections to chasis and to engine.

The Transmission Range Sensor (TRS) switch that is on top of the transmission.
This is also called "neutral safety switch".
Prevents the engine from being started in any gear selection other than Park or Neutral.

Yes, it is possible to have a problem come up that has nothing to do with a repair that you just did.
Although......really checking what you just did is the first, and most logical thing to check.

[searcherrr]

I know this was a while back now, but the extremely squeaky pulley turned out to be a water pump going bad. Anyone who has this should immeidately consider replacing their water pump.