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This is not the instalation instructions for the instalation on a 96 Ford Mustang. This I can get myself. This is the rebuild instructions for the powerdyne bd600 supercharger head unit. I need the install instructions for the complete powerdyne bd600 kit onto a 96 Ford Mustang 4.6l This is not the instalation instructions for the instalation on a 96 Ford Mustang.
This I can get myself. This is the rebuild instructions for the powerdyne bd600 supercharger head unit. I need the install instructions for the complete powerdyne bd600 kit onto a 96 Ford Mustang 4.6l. Disassembly:.
Remove pulley mounting bolt and centering washer from the pulley with an impact wrench. While you have the impact wrench, flip over the head unit and loosen the impeller holding nut. They are both counter-clockwise to loosen.
Remove 14 SAE hex-key bolts from front cover. Remove 7 bolts from volute cover. Note position or orientation of volute to the head unit. Use a magic marker or a scribe to draw a line to note clocking position. This will save you time on assembly later.
Flip over and tap volute off of back with a plastic or rubber hammer from side to side. Remove impeller and impeller shims.
Using pulley puller, remove front pulley. If it does not want to remove easily, heat it up in an oven or a crock-pot/electric skillet for 20-40 minutes with the pulley face down. It should then be able to be removed.
Remove the hex-key. Heat the rest of the head unit for about 20 minutes in an oven at about 250 or about 40-60 minutes in an crock-pot/electric skillet with a lid on high. Using gloves to hold the head unit, tap the front cover from side to side to remove. Once the centering pins are exposed, you can plastic or fiberglass pry bar to pop the top off. There is a large flat metal spring behind the drive bearing in the front cover.
Note the installation position in the case. Once the top is off, flip the unit over and place in a press.
Position the unit in such a way that the impeller drive shaft is vertical. Using light pressure and a centering pin on the shaft (to avoid damage to the threads), press the shaft out of the housing. You may find it easier to rotate the belt off the drive hub as it is being pressed out. If you do not rotate the belt off of the large drive hub, the belt keeper washers on the small impeller drive shaft can become bent or damaged. Flip the unit over. Using a specially designed c puller, pull the large drive hub out of the head unit housing. There should now either be bearing left in the housing, or on the drive shaft and impeller shaft.
Removing them from the drive shaft is easy with a bearing press and bearing puller. It is best to reheat these bearings in a crock-pot before removal as they pop off with little effort. Remember, the more force you use with the bearing press, the likely chance you can warp or bend a shaft, especially the impeller shaft. If the bearings remained in the head unit housing or the front cover, the use of a blind hole bearing puller will be required. Heating these pieces up as well to remove the bearings.
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Some units may have belt tensioners installed inside the unit- take these out and toss them away. Powerdyne converted the units over to a different belt in later years. The replacement belt from above will not require these parts.
Now is the time to inspect all pieces. Check the shafts for nicks, bent belt keepers, bearing pockets for damage, damage to case mating surfaces, impeller damage, volute damage from scraping, belt damage, shaft damage, check all thread holes.
Once all items are inspected, now is a good time to bead blast any items that show corrosion or just to give it that like new appearance. Thoroughly clean and blow off all parts and bolt holes. Assembly:.
Now that you have inspected and cleaned all items, it is time to put the many pieces back together. Place both the drive and the impeller drive shaft in the freezer. After they are frozen, drop all the bearings into the surface of a crock-pot or electric skillet. Don't let them get too hot as you do not want to cook the grease out. Once they have reached temperature, remove the shafts from the freezer and position the impeller shaft into a bearing press.
Use some light oil or grease on the shaft to aid bearing movement and remember to use the correct sized press collar to push the bearing from the inner ring onto the shaft. This should not take much effort. Repeat for opposite side. Once the impeller shaft is completed, repeat the same procedure for the drive shaft. Now take the front case and head unit case and preheat them in an oven or a crock-pot. Place both shafts into the freezer.
Once the case is warmed up, place the drive shaft into the head unit case. Take the belt and the impeller shaft and position them into the head unit case. Use the press with light pressure to position into head unit case. Rotate the belt and the impeller shaft from time to time as this is the only way to place the belt without any difficulty. If the top case has a front seal, replace it now. Reinstall metal spring into place on the front cover with a small amount of thick grease. The grease will help hold the spring into position when you flip the cover over.
Position the heated top cover into place and line it up with the pins. Using the plastic hammer and a board, use light taps around the edges of the case until it is fully seated. Insert case bolts and torque to 7.5 ft lbs.
Rotate head unit over. Place the same shims that were under impeller before into place. Install impeller.
Install nut on impeller with a small amount of lock-tite. Position a piece of bicycle inner tube on drive shaft where the drive pulley would be installed. Place drive shaft and inner tube assembly into vice.
Using impact wrench with 90lbs of air, impact nut briefly into place. Remove from vice and remove inner tube. Install volute and note the correct orientation that was marked during disassembly.
Insert 7 bolts into position and torque to 9 ft lbs. Using a brass feeler gauge of.010, insert down the side of the impeller exit. It should be able to slip inward about 30mm. If the feeler gauge will not slide into position, disassemble volute and impeller and remove a shim. Reassemble using previous procedure and try again. If you can insert a.012 feeler gauge the same distance, then the impeller needs shimmed higher. Remove volute and place a small amount of play-dough on the inside of the volute near the last 30mm of where the outer impeller would be.
Reassmeble and torque bolts to spec. Now disassemble and inspect the thickness of the pressed in lines from the impeller.
They should be.010 +/-.002. If it is thinner, a shim will need to be removed. If it is thicker, you will not be able to add a shim as it will change the specifications of the previous measurement gauges on the impeller exit. Remove play-dough and reassemble volute again. Place front pulley in the crock-pot. Heating up this way will make installation easier. Reposition the hexkey and the pulley.
Tap pulley into place with pla.