I have saw a few posts and some videos online. I just bypassed my 2004 4.6 XL compressor. Trucks frame is rusty so even though I have all the stuff to redo AC not wanting to. I used duralast from AutoZone. The pulley was part 240151. It is grooved so run around the outside of it and used a 840K6 belt. It squealed when I put it on so I switched the old idler pulley that was larger with the stock tensioner pulley and that gave me enough tension to stop the squeal but still enough play to easily install the belt. I hope this helps anyone looking to do the same. Parts were around 60 bucks.

 

i did a bypass too. carrying the pArts (or at least knowing what parts to get ) can make an quick/cheap solution to what would otherwise Dead on side of road situation (if your compressor fails).

I have a thread on this too that includes a link to a youtube video that i followed.

 

It's going to be a long hot summer
Why not fix it?
Granted, it's not easy to replace a compressor on one of these newer trucks

 

So did you have to replace the tensioner pulley and the idler pulley above it to both grooved? What was the size of them?
Also did you run the new 840k6 belt on the outside(left side looking at the engine) and it so does the belt need to be put on prior to replacing the tensioner pulley? Because I don't see a way to get the belt on the outside of it with out removing the tensioner pulley. I'm trying to bypass my ac compressor as well, bolts broke off when replacing the crankshaft sensor. Thank you

 

use advance search, for threads started by me, keyword: a/c