Thanks Jack.

I'm starting to think this upgrade should be on the list for bulletproofing 03's and 04's.

 

Yeah. I added a comment while you posted.

 

I absolutely used the holes to stop rotation. I tried lots of different things the first time I had to break the fan nut. For lack of any local supplier having the correct tool, a long 3/8 ratchet extension through one of the holes and butting against a rib in the water pump was the winner. And that's when I could see it flexing.

 

I used this tool.


not the easiest to use, but I didn't see any flex. Diesel Tech Ron has a video showing him using a chatter gun and chisel on the fan nut, not one of his best pieces of advice.

 

That's what I looked for locally and couldn't find. It's on my wish list. Fortunately I didn't need it yesterday. With the pulley in two pieces I was able to get the water pump mounting bolts out and remove the whole assembly and put it in the bench vice.

 

It doesn't matter if it's the common tool, screwdriver, pry bay or socket extention, there will be torsion to the pulley. One could argue the impact hammer has the least potential for distortion, but you'd need to strain gage the pulley to know that.

I used the common tool, broke its tip. Used a socket extension, still couldn't break the fan nut loose. Ended up doing the impact hammer and that worked. Since then the threads have been coated with antiseize and snugged only. Still can be tempormental.

 

I put blue locktite on the fan threads too. Gonna take a lot more effort getting it off next time, not being able to unscrew it most of the way by hand and all. But I'll sleep better not worrying about the fan unscrewing itself.

On the bright side, I did the Bullet Proof Diesel 7.3 fan clutch conversion a few months back, so now I can put a wrench on the adapter nut while unscrewing the fan nut with another wrench. That's an advantage nobody ever mentions. No more stress on the pulley, and no special tools. I guess I can take that spanner off my wish list!

Edit - I just remembered the bore in the pulley won't clear the corners of the adapter nut, so I will need the spanner if I need to replace the water pump.

 

Obligatory "That'll buff out" or "It still has a few miles left on it" post.

 

That failure is common on the 03' and 04's! I had it happen to me.

The fan was on so tight that i had to pull the water pump, fan and inner shroud as one unit. I ended up cutting the pump apart, welding the flange to a welding table and had a buddy help me break the fan loose.

In all honesty I would recommend to replace the pump with an OEM one just for piece of mind! It is a sucky job to have to redo it.