I was replacing the alternator on my 2002 Expedition and when replacing the belt, I broke off a pulley. The pulley above the tensioner cracked off the cover. Now I need to replace it. Where do I start? What is the level of difficulty? Can I do it without pulling the engine? What is the name of the part I need to replace and where can I get a new one?

 

I think I can replace the Timing cover with the engine in place. Do I need to drain the oil first? Then, Can I remove the Alternator and power steering pump? Then unbolt the cover, pry it off and replace it with a new gasket. Is there more that needs to be removed?

 

You can view the manual and get an idea of difficulty. Looks like plenty are available on E-Bay. Is yours the 5.4?

FORD 5.4 SOHC ENGINE TIMING CHAIN COVER 2002-03 #13060/15525 | eBay

 

I have the 4.6.