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1-ton Idler arm upgrade parts maker?

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Old Nov 3, 2024 | 07:35 PM
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This is an old thread but worth updating:

I was able to almost finish installing the 1-ton idler arm upgrade today.

I was able to make the Proforged idler arm shaft body fit by using my Dremel Tool. I first started eye-balling where to grind away based on lining up the bracket and the shaft body. But as I got close I used masking tape to find out where the interference was with just the lower bolt installed. This worked really well. I tried not to take more than needed, although I likely could have done a tad more since once I got the bracket installed, having a bit more extra wiggle room would have made the installation a bit easier.

The Outfitter Design people are supposed to have redesigned the bracket to accommodate the taller Proforged idler arm shaft body by the time of this update, so perhaps this update will not be needed much.

A final note: If you still have your fan shroud for the stock radiator fan, it can get in the way. This was very much the case with my larger radiator that resulted in the shroud being a bit further to the rear. This resulted in the need to cut a notch in the fan shroud for the top corner of the idler arm bracket and the shroud being in the way when installing the idler arm shaft body.

Where the bracket was touching the fan shroud. A hack-saw blade in a holder made short work of cutting a notch in the shroud.
Where the bracket was touching the fan shroud. A hack-saw blade in a holder made short work of cutting a notch in the shroud.


The witness marks showing where the top of the Proforged idler arm shaft body was hitting the top inside of the bracket. If not worn through the tape, I'd cut out the tape that had been contacted and then marked the metal with a Sharpie pen. Then with the tape removed it was easy to see where to grind the excess material.
The witness marks showing where the top of the Proforged idler arm shaft body was hitting the top inside of the bracket. If not worn through the tape, I'd cut out the tape that had been contacted and then marked the metal with a Sharpie pen. Then with the tape removed it was easy to see where to grind the excess material.


The final amount of grinding I did. If I had started with the tape trick to locate where the interference was, I likely could have gotten away with grinding away much less of the metal.
The final amount of grinding I did. If I had started with the tape trick to locate where the interference was, I likely could have gotten away with grinding away much less of the metal.


Almost installed. I purchased 1/2
Almost installed. I purchased 1/2" diameter bolts for the last two mounting holes as I these would fill the holes better than the original idler arm bolts that are only 12mm. I removed the brackets for the securing the brake line that goes from left to right so that I could have enough slack it in so that it would not touch the idler arm bracket.

 
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