I started getting a loud chatter noise under the hood. After ruling out a few other things like a loose exhaust pipe, I pulled the belts off. I followed the noise to the bottom of the engine where I could actually see the main drive pulley pulsating and vibrating. The noise coincides with the movement of the pulley.

Now what?

Does this mean a bad harmonic balancer or am I looking at bad drive bearings?

Has anyone replaced a harmonic balancer before ? It looks pretty tight in there. . . .

If it is a balancer, could it cause any bearing problems if I keep driving until I fix it?

If the noise is still there with the belts removed, it is not likely the harmonic balancer. Removing the belts makes the noise stop. It would also stop when the engine is revved a bit with the belts on. It sounds as if you may have something more serious going on. Have you had any problems with losing coolant, or any other issues?

If you want more information on the harmonic balancer, do a search on the 92-99 section. It'* covered well there.

I didn't explian very well.

When the belts were off, the noise did stop. When the engine is reved, the noise does stop and as I let off the gas the noise picks up again.

I will look in the 92-99 section.

Look for cracks around the balancer. Bill Buttermore had a write up on removing the balancer. This is a link on replacement. A large screwdriver pushed into the teeth of the flywheel can be used instead of the special tool.
Crankshaft Balancer Replacement
You may be the first in 00+ crowd to have a problem with it.

Is that picture showing the engine upside down Archon?

Anyway, it looks like the balancer and pulley are one unit. Some of the old Fords would have the pulley bolted to the front of the balancer. This way of having the balancer and pulley as an integral part is a good idea.

I pulled mine off the 00 engine using a impact gun and with a wrench on the fly-wheel to prevent it from turning. I then used a large screw driver to give it a little nudge to slide off once the bolt was removed.
If you want I'll sell you my spare (42,xxx miles old), but be certain you need it. $70 shipped sound ok? They're well over $150 new I'm sure (haven't checked -they could be over $2-300 new for all I know).

I've watched my neighbour use an impact gun for removing the crank bolt without holding the flywheel; it was on a Honda though. He just pulled the front wheel off to access the balancer and went zip zip.

Yeah, Mac..it is. I hadn't noticed that!

With this statement I believe that it is possible to separate them.

Yes, it is possible to remove the bolt for the balancer with air tools without holding the flywheel in place. No air tools? You'll have to secure it.

A balancer/pulley is one unit. They are designed and made that way, no way or need to seperate.

To pull the balancer. If you have a serious impact gun... you can knock struggling and 30 minutes off your time.

Bascially you jack and support (make sure because you are going to struggling.) the passenger side front.
Remove tire and shielding to the balancer area.
Remove belt and balancer bolt.
IIRC the bolts to the balancer are M6 or M8..you'll want 80-90mm long bolts.
Pull balancer, put new one on..paying attention to the keyway on the crankshaft for alignment (make it eaiser to put on)
Use HB bolt to pull balancer back on..
Belt back on..
Button it up and call it good.

With an air gun.. it takes me about 15 minutes start to finish. With out..I think it took two of us.. an hour in a parking lot.

Marty.. new balancer shouldn't be more than $120 shipped. I've also go a balancer sitting around. Would be happy to see it leave my garage. Say $40 shipped to the US, via priority mail. .

It'* good to know I have been the ground breaker for 00+ crowd for having a balance go bad. The stealership said that they don't see these go bad very ofter either. Just my luck. My list of problems grows by the week with this car.

Tonight I am going to check the rubber, just to make sure that is what my problem is. If it is bad, will there always be cracks, or is there something else I should look for?

The stealership wants $209 for a new balancer. If you guys have a used one to sell, I am interested, as long as it is in good shape. I don't want to have a repeat failure. OLBlueEyesBonne, you were the first to offer, but Bill is half the price. Bill - is yours in good shape?