After some good advice in the comments section, and the helpful folks over at Ford Truck Enthusiasts forum, I determined that the old pulley was toast and ordered a new one from Ford ($75.00) to go with the new vacuum pump from Auto Zone ($100.00)
The old pulley was pretty messed up after I reamed on it, beat on it, heated it with a torch, and beat on it more. It was rusty anyway.
The pulley installer/puller kit I got from Harbor Freight ($14.00) didn't quite fit under the flange on the pulley to remove it. Somebody on Ford Truck Enthusiasts suggested grinding it down so it fits. Good idea, but a project for another day, now.
Here is the puller kit, next to the new pump and pulley.
After a 4 hour bus trip to and from the Ford dealer, I retrieved my pulley, and with a little figuring and much clamping and elbow grease got it pressed onto the pump. The Ford dealership wanted at least $70 to put it on, and I think the service guys were annoyed that I was doing my own work instead of letting them rip me off.
I DON'T trust dealers. Been there, been screwed.
I'll install the pump tomorrow. That will be easy compared to the pulley ordeal. Now I have to clean the house since company is coming in for French Quarter music festival.
The poor kitties know changes are afoot. They follow me around meowing at me.
Fluffy kitty Cleo says, "I know you're leaving and you're gonna take me with you if I have to stay permanantly attached to your suitcase."
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