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YOUR RESEARCHidler pulley - failure & replacement
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Replace 3 pulleys as they're all the same age
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Suggestion · Original poster
I decided to replace all 3 pulleys as they're all the same age.
Leading evidence: 'Replace 3 pulleys as they're all the same age' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, The most frequently discussed action is 'Replace 3 pulleys as they're all the same age' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
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Suggestion · Original poster
So I had to press that bushing out to use the tensioner pulley bushing that came off the car
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I have a 2004 996 Carrera with original idler pulleys that recently failed. The bearing gave warning before it failed by sounding louder than normal. When it failed, the belt came off, lots of burnt rubber smell, and smoke from the rear engine area followed by no power steering and an electrical warning. I stopped the car and got it towed home. I have 50k miles on the car so the bearings do dry out with age.
The lower idler pulley was the one that went bad, see pic w/ rubber belt on pulley. I decided to replace all 3 pulleys as they're all the same age.
I opted for 3 URO pulleys from rockauto. A couple of things of note:
all 3 pulleys (2 x idler, 1 tensioner) are exactly the same except for the mounting hardware (rear bushing, front washer)
I ordered 2 upper pulley (
99610211856) and 1 lower pulley (99610211858) since rockauto didn't have a tensioner pulley for my car
The upper pulley has a bushing pressed into it from the factory. So I had to press that bushing out to use the tensioner pulley bushing that came off the car
If i had to redo, I would buy the lower pulley (
99610211858) since the the busing is not attached and use it as the tensioner pulley with tensioner bushing
I measured the bearing circumference after pressing out bushing and it was exactly the same as the OE part, perhaps URO just made the bushing too large.
The car is much quieter with the new pulleys.
Bushing that's too large on right that needed to be pressed out.
Rubber on pulley after failure.
Not on the porsche but i had one in a jeep actually leave the motor and go bouncing down the parking lot. It happens but usually there r signs and strange noises should not be ignored.
If you had followed some kind of preventive maintenance program, this would not have happened.
At 60,000 miles, all belts, pulleys, bearings, water pump, and thermostat, and AOS are pre-emptively changed.
