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2-1/2 Pulleys in 2-1/2 Hours.....
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Posted by Roger (more from Roger) on Mon, 12 Apr 2004 15:08:08 Share Post by Email
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The half pulley because I was forced to reinstall the old pulley on the belt tensioner since the new pulley bought on-line didn't fit properly.

Wray - You're a genius for your tip to use criss-crossing tape to hold bolt and washer in place to get the center (and toughest) pulley installed.

To all D-I-Y'ers contemplating doing this repair, buy all parts from your local dealer, or buy OEM Saab parts. I am "0 for 3" with my on-line pulley purchases. Dealer cost for OEM parts was only $10 more each than aftermarket parts bought on-line which didn't fit right.

1) The upper grooved pulley would not fit with existing hardware because it was made with flush sides and my car used a deep conical washer with the securing nut. OEM part from Dealer was exact match for old style and is now installed.

2) The tensioner pulley bought on-line was manufactured wrong. The reinforcing ribs bridging from inner to outer hub were insufficiently machined to allow clearance with tensioner. Tightening the nut resulted in the pulley not turning. OEM part from Dealer was bought on a second trip to their Parts Counter and will be installed next weekend.

3) The center pulley bought on-line was listed as a 9000 and 9-5 part. It was slightly larger diameter than original. As tough as it is to replace that pulley, there was no way I was going to do it twice! Bought an OEM replacement at Dealer and it was corect diameter. It is now installed.

Next I will be trying to get credit for my returned 3 pulleys applied to new PCV hoses.

Final note. At 106,800 miles the small grooved pulley had a distinct clicking sound when spinning it on my finger. This may not have lasted until my second belt change at 120,000 miles. I probably got it just in time! The other two old pulleys still felt and sounded fine when doing a finger spin.

2000lpt Sedan
106,800 miles

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