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I removed the third set of idler pulleys from my car for inspection and replacement. As expected the upper, OEM ribbed pulley bearing was worn out after about 40k miles on the car. (see previous posts by Dean & others). Lower pulley was fine after same mileage.
Covered here before, but for what it may be worth to someone else:
Bearing on the ribbed pulley had too much side-to-side play in it, and holding it up to my ear, clicking could be heard while spinning the bearing, or shaking the pulley in my hand. I would NOT want to re-lube this bearing. One more like it and I could at least make a set of Maracas...
The lower, smooth idler pulley was in good shape. It is about 25% larger diameter than the ribbed pulley. Turned freely with no excess spin or play in the bearing. It had been replaced with a Dayco pulley last time, and could probably easily match or exceed the 60k mile belt life.
Comparing the worn pulley with one supplied by local Saab dealer this week in a box labeled "Saab Genuine Parts, 4356127", they are the same type and manufacturer.
As other people have posted, removing the lower pulley is a pain, and was only accomplished with the help of some PB Blaster, a Craftsman combo 6-point-box/open-end 1/2-inch wrench and a 1/2-inch drive ratchet inserted into the open end for leverage. The bolts for both pulleys on my car are actually 13mm, but the lower one is not accessible with a socket. Rounding off the bolt with an adjustable wrench seems like a definite possibility, so do skinned knuckles. Bypassing that pulley with the short belt would save some time and expense.
References:
Saab ribbed pulley: OD 64mm, FAG Hungary, with bearing OD 44mm, bore 8mm, labeled HSR. Not a standard bearing size I can identify, bearing failure at 40k miles. $44 list at Saab dealer, less online at a couple of the site sponsors.
Dayco smooth pulley: OD 80mm, Dayco, standard 6203 40mm bearing (6203RR9D, OD 40mm, bore 17mm). Not sure where that one came from, closest readily available Dayco equivalent is Dayco p/n 89017, 76mm OD with same bearing, $15.94 at Advance Autoparts.
PB Blaster spray can
1/2" 6pt. box end combination wrench
1/2" ratchet or handle of any type for more leverage
Michel Briand's web site (short belt mod):
http://pages.infinit.net/mlbriand/index.shtml
1996 SE turbo
100k miles
posted by 69.211.13...
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