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Re: Broken Square Lug on Belt Tensioner
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Posted by bill h. (more from bill h.) on Sun, 3 Mar 2002 12:37:15 Share Post by Email
In Reply to: Re: Broken Square Lug on Belt Tensioner, Martin Barnes, Sun, 3 Mar 2002 03:35:00
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Martin;

This is what I paid (http://www.Eeuroparts.com)- in USD;

belt - 25.90
tensioner pulley - 22.90
big idler pulley - 29.00
tensioner casting - (from local junkyard - I had to remove it from a wrecked car under the watchful eyes of three drooling Rottweilers) - 2.00 (not including cost of cleaning underwear)

True, it is possible to MAKE these of Al (OEM are merely plastic) provided you have the material, lathe, drill press and are a reasonably skilled machinist, but the little pulley you will see has grooves that must precisely match those of the serpentine belt you just installed. This would be the tough part. I used to be a machinist in my college days and I wouldn't go this route. Instead, I recommend you find the best price you can, use the internet as your local supplier may be a little steep as based on my last visit, to NZ, Saabs were a rare sight.

You have already made a tool to deal with the broken casting (it being the most expensive part if you purchase a new one), unless of course you can find a "used" one in good shape like I did, you can likely live with it if it not bent or twisted along the axis.

You are on to something about the bearings though which may present another option, and probably the most cost effective for you. The reason the pulleys fail is due to the fact that Saab used substandard bearings. Remove the pulleys, get out your calipers and measure the bearings ID, OD and width. Go to your industrial bearing shop and buy identical sized QUALITY SEALED bearings that require no lubrication. Squirt some penetrating oil around the edge of the bearing and carefully press out the old bearings in a vise using an appropriate round barstock or socket (dont break the plastic). Put the new bearings in the freezer overnight and you should be able to just drop them in to the plastic pulleys the following day without pressing them in. Reinstall, and you now have solved your potential dilemma, have a better than new pulley, and saved some cash in the process. I find this size bearing ran 6.00 - 8.00 USD from my past experience with older Saabs (pre-94).

I had to improvise a lot when we sailed from the US to Aust in a 45' sloop, our Yanmar diesel failed 200 nm from NZ, I had to become an expert in diesel repair overnight and had to rebuild it with parts from - guess where - Auckland!

Good Luck,

Bill H.
Georgia, USA

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