Originally Posted by Locobob (Post 294224)

Well I pulled the belt off and the pulley seems to spin freely by hand... although that doesn't mean it doesn't perform differently under load. The belt doesn't look terrible, its a little chewed up in a couple of spots. I need to check my notes for the belt size, I have the underdrive pulley set from SRP. I have Gates and Dayco pulleys available locally. I believe Gates is supposed to be the gold standard but with all the outsourcing going on who knows anymore. I did rebuild the tensioner a few years ago because it was chattering badly, I haven't seen any sign of it bouncing around since so I'm guessing that part of the assembly is okay.

Originally Posted by Dynomite (Post 294225)

Did you modify the Tensioner such that the pulley inner hub was not in contact with the tensioner at any place? Take a close up photo of the Aluminum Pulley belt surface. Also a close up photo of the failed surface.

Was the Pulley Bearing Snap Ring on the outside or toward the engine?

Originally Posted by Locobob (Post 294226)

I'll have to take a look at that once I get the tensioner out. I don't recall any modification being necessary.

Originally Posted by Dynomite (Post 294227)

Originally Posted by Locobob (Post 294228)

Now that I think about it I may have done that... looks familiar, I think I may have used my die grinder and a sanding drum and beveled that edge

Originally Posted by Dynomite (Post 294237)

If you did that (used die grinder on interference issue) and the bearing is fine now.......we are back to Phil's suggestion (Fatigue). Or..........."your combination of stuff" rebuilt Tensioner.

It sounds from your description that the Serpentine belt was very loose toward the end which means the pulley was not held tight against the belt. But the pulley could spin freely? Maybe you should go back to the "factory Serpentine Belt Tensioner".

Originally Posted by Locobob;294244[B

[/B]]No the belt was nice and tight, I removed the belt before spinning the pulley. It spins without a load on it but that doesn't mean it would do the same under load. I rebuilt the tensioner about 2 1/2 years ago using the original, some L98 parts, and the aftermarket aluminum pulley. Hopefully that makes it clearer.