The only idea that I had on why it is not fitting is somehow the engine has twisted....how I have no idea. I did try pulling on it just to see if there was any movement.....nothing.
I did compare the poly to the OEM one and the OEM one is offset from being centered...not by much though.

I decided to just leave it alone for now, started working on replacing the front cover.....that had not gone well at all. I am not able to get the fan clutch off. The belt would not hold at all....just slipped. I tried to find a way to jam the water pump pulley...but never was able to. So now I have a strap wrench on the pulley but I am not able to use a hammer to strike the wrench as not able to keep tension on the strap wrench. So I have been doing the pushing the strap wrench and pulling the wrench on the fan clutch nut.....and getting nowhere! The strap wrench holds fine, just not able to get the fan clutch nut to break free.
About ready to call a mobile mechanic to come over with the air tools to get this....that would not be cheap!

 

I've had good luck using an old belt wrapped around the pulley and pulled tight with a ratchet strap. That way, you can use both hands.

 

Do you have wife/gf, or anyone who can help you or are you doing this yourself?

 

Are we talking about that big old fan clutch bolt? I've out a wrench on it that was long enough, I was able to give it one good whack with a hammer to break that initial tightness, then do the rest by hand.


notice you tried that. I was able to do it with the stock belt on, are you able to put it back on to loosen the bolt?

 

You are turning it the right direction?

 

Quick update: I did get the fan clutch off. A trip to O'rielly Auto Parts to get the fan clutch tool set; after getting the tools in place, took me less than a minute to get it to break free. Yep, had to use a hammer and several blows....yep, turning it in the right direction (was waiting for that one). After getting it off I saw why it was being so difficult...red thread locker......did it's job!

Back to working on why the poly mount is not fitting.

 

Progress Report: no progress on the poly mount. After getting the fan clutch off, I removed the crankshaft pulley. Was going to pull the harmonic balancer off, but did not, decided to pull the spark plugs out instead. Managed to destroy the two straight plug boots on #1 and #6. For some reason they just would not come off the plug, the wire broke and the terminal pulled through the boot. So time to replace the 7 yr old wires.....

Have been reading-up on dropping the front diff/axle down to drop the oil pan.....not getting much of a "warm fuzzy" about success. Seems there is a nut inside a fame rail and the access hole is too small, also requires an offset 18mm wrench. Others have cut this angled bracket off, then re-welded it back. Do not have an 18mm offset wrench nor a welder.....so not sure how far I am going to get. Hopefully I will be able to drop the oil pan just enough to remove the timing cover without damage to the oil pan gasket....will see what happens.

 

I was able to do my front diff drop with ratchet wrenches for all the bolts. But you gotta be careful not to drop anything in the frame... wasnt fun getting them out lol.

 

Today's update: I got the poly engine mount to fit just fine. I loosen the poly's three mounting bolts and with some pulling on the engine I was able to get the frame bracket bolts to align...YEAH!!!!
I also removed the harmonic balancer; came off quite easily...which actually bothers me a bit as to why it came off some easily.
I also got to loosen all the oil pan bolts, even the one on the left side directly above the front diff. Took me about four tries but I did get it. Not sure how I will ever get it back, but it is out for now.
I found the front diff mounting bolt with the nut inside the frame and the too small a hole for a wrench. It would require removing the left shock and upper control arm just to get to this nut.

Then I saw that the starter's dust shield had small bolts into the oil pan, one under, one above....so these needed to come out. I thought, no big deal,,,just take the starter out. Got the two mounting bolts out, but have not been able to get to the terminals. Thought I could drop it down...nope...starter will not pass through....looks like the engine has to be lifted to get the starter out....really!!!.....


I am about to the point of just pulling the engine out....it would likely be less trouble/effort/time. I sold my engine hoist and engine stand some years ago....so I would have to go shopping on Craigslist.

 

I read somewhere that these trucks were assembled by installing the motor and drive-train first and then the body was lowered down on to the frame. And with these being pretty small trucks (at least by today's standards), there is just not much room.