1989 Georgie Boy Ford 460 Engine Belt Routing Diagram & Replacement Parts Guide

Quick Take

Your 1989 Georgie Boy Encounter with the Ford 460 engine typically uses a two-belt system - separate V-belts for each accessory - typically one for alternator, one for power steering pump, one for A/C compressor (if equipped), and one for water pump and fan. Since the belts broke after the alternator replacement, they were likely installed with incorrect routing or tension. You'll need the correct V-belts for each accessory (verify specific part numbers with dealer), and the correct water pump belt (verify with dealer - approximately 112 inches). Getting the routing diagram from a Ford service manual or parts store will be crucial before attempting reinstallation.

Common Causes

Belt failures immediately after alternator replacement on your 1989 Ford 460 commonly include improper installation. Another frequent issue is over-tensioning the belts during installation - the Ford 460 uses a manual tensioning system, and many people apply too much tension thinking tighter is better.

Incorrect pulley alignment can also cause problems if the alternator wasn't positioned properly when tightened down. The alternator bracket has adjustment slots, and if it's not aligned correctly with the other pulleys, it will cause the belt to run at an angle and fail quickly. Additionally, if any pulleys were damaged during the original repair or have worn bearings, they may not spin freely, putting extra stress on the new belts.

Sometimes the issue isn't the installation but rather debris or damage from the original belt failure. If pieces of the old belt got wrapped around pulleys or the fan, they can cause new belts to track improperly or create vibration that leads to premature failure.

Preparation

⚠️ SAFETY WARNING: Always disconnect the negative battery cable before working on belt systems to prevent accidental engine start-up or electrical hazards.

Before starting, you'll need to identify the exact belt configuration for your 1989 Georgie Boy. Contact a Ford dealership parts department with your VIN, or visit an auto parts store where they can look up the specific belt numbers for your 460 engine. Most stores can print out a belt routing diagram, which is absolutely essential. You'll also want to purchase both belts at the same time, even if only one failed, since they're likely the same age and the other may fail soon.

Gather the necessary tools: a 1/2-inch breaker bar or large ratchet, sockets for the alternator and power steering pump bolts (typically 13mm or 1/2-inch), and a belt tension gauge if available. A flashlight or work light is crucial since the belt routing can be difficult to see in the engine bay. Take photos of any remaining belt routing before removing broken pieces, and clean all pulleys thoroughly with a wire brush to remove any rubber debris.

Check all pulleys for damage, wear, or wobbling by spinning them by hand with the engine off. Any pulley that doesn't spin freely or shows signs of damage should be replaced before installing new belts. Also inspect the belt tensioner mechanism - on the 460, this is typically a manual system using the alternator's adjustment bracket.

Repair Steps

⚠️ SAFETY WARNING: Ensure engine is completely cool before working near moving parts. Keep hands and tools clear of the fan and pulleys.

Start by completely removing all broken belt pieces and cleaning debris from all pulleys and the engine bay. With your belt routing diagram in hand, identify each pulley: crankshaft (largest, at the bottom), alternator, power steering pump, A/C compressor (if equipped), water pump, and fan. Each V-belt routes between the crankshaft pulley and its respective accessory pulley - alternator belt, power steering belt, A/C belt (if equipped), and water pump/fan belt.

Install the water pump/fan belt first since it's usually the inner belt. This V-belt goes around the crankshaft pulley and up to the water pump pulley. Loosen the fan shroud if necessary to get the belt over the fan blades. Adjust tension by moving the water pump or using the adjustment bracket - the belt should have about 1/2 inch of deflection when pressed firmly with moderate thumb pressure (approximately 10 pounds of force) at the longest span between pulleys. Use a straightedge ruler to measure deflection accurately from the belt's normal position.

For the serpentine belt installation, start by loosening the alternator adjustment bolts to create slack. Route the belt according to your diagram, typically starting at the crankshaft and working your way around each pulley. Make sure the belt sits properly in each pulley groove - it should be centered and not riding on the edges. The ribbed side of the belt goes against grooved pulleys, while the smooth back side runs against flat pulleys.

Adjust belt tension using the alternator bracket and torque all fasteners to manufacturer specifications. Each V-belt should have about 1/2 inch deflection when pressed firmly with moderate thumb pressure at the longest span between pulleys. Use the same measurement technique as the V-belt for consistency. Too tight will cause bearing damage and belt failure; too loose will cause slipping and squealing. Start the engine and let it run for a few minutes, then recheck tension as the belt may stretch slightly. Listen for any unusual noises that could indicate misalignment.

When to Get Help

If you cannot locate a reliable belt routing diagram for your specific 1989 Ford 460 engine configuration, stop and seek professional help. Installing belts incorrectly can cause expensive damage to the alternator, power steering pump, or other components. A Ford dealership service department or experienced RV mechanic will have access to the proper diagrams and specifications.

Call for professional assistance if you discover any damaged or wobbling pulleys during your inspection. Pulley replacement often requires special tools and precise alignment, and attempting it without proper equipment can lead to recurring belt failures. Similarly, if the alternator bracket appears bent or damaged, or if the alternator doesn't align properly with the other pulleys, you'll need professional repair to avoid repeated problems.

If belts continue to break after proper installation, there's likely an underlying issue such as a seized pulley bearing, misaligned component, or internal engine problem causing excessive vibration. Professional diagnosis will be needed to identify and correct these root causes before you end up stranded with another belt failure. Don't attempt multiple reinstallations without addressing the root cause, as this can lead to damage of expensive components like the alternator or power steering pump.