Idler Pulley - Fell off !

[gathomas]

I would like to know if anyone has had the misfortune to experience what I did about two months back in July. I was parked in a Flying J off I-95, just North of Richmond, VA 11pm, idling with A/C on (hot & humid) talking on cell. I had just got off the highway about 15 minutes, then I heard a loud noise from under the hood, I immediately shut the engine down and popped the hood to investigate. It didn't take long to discover a broken serpentine belt, 92,000 miles on OD and no spare belt, (there's a lesson here).



I called AAA for assistance, when the Driver arrived we were looking over the damage and he discovered a "Pulley" laying at the bottom near the Radiator.



We were surprised to find this pulley. Next, where did it belong ??



To keep this story from becoming a novel - this pulley is an idler, at the top of the engine, hidden by Rad hose. Tensioner pulley is lower.



I was towed to garage at 4:30 am, Eleven hours later and $1100 lighter, I was back on the road to Pittsburgh (Beaver,PA).



Anybody ever had this Pulley snap off ? held on by basically a 3/8 bolt, I know its Metric, just don't know the size. Owning a Cummins and having something this stupid to happen - I'm at a loss for words... LOL. . https://www.turbodieselregister.com/images/smiliemile.gif



2004. 5 3500 DRW Quad Cab, Auto, Bilsteins ,Amsoil everywhere, Smarty Jr, 2wd

 

[GCordrey]

Been there,done that, got the shirt to prove it...

I had mine start making noise while I was pulling firewood out of a hollow in light rain. By time I had muscled my way up and to the house, the racket was pretty bad. I had about the same on the clock as you have. For some silly reason, I thought this would be covered under the Cummins warranty. (NOT!)



It didn't fall off, but it did when I started wiggling it! That has some force behind it!

 

[WCounts]

I believe some where arround 80-90K miles the belt should be removed and replaced allong with the tensioner pulley. While off anything the belt pulls should be checked for play and smoothness. After installing a new belt and tensioner pulley I like to make sure the belt is running in the center of the tensioner pulley. If it's not I would change the tensioner.

Billy

 

[absocountry2]

Mine came loose also, broke belt

I had the bolt come loose on mine at 110,000 miles. No warning, belt broke on startup. The belt wrapped around the crank and wrapped around the tensioner, snapped tensioner. Best place to purchase tensioner is from Cummins $85, NAPA $190, Schucks $180. I installed a new belt and it broke on the third start after replacement. That is when I found the idler loose. It is a 13mm head on the bolt. It seems this might be something to watch, maybe locktight bolt when replacing belt.

 

[gathomas]

Idler Loose

I had the bolt come loose on mine at 110,000 miles. No warning, belt broke on startup. The belt wrapped around the crank and wrapped around the tensioner, snapped tensioner. Best place to purchase tensioner is from Cummins $85, NAPA $190, Schucks $180. I installed a new belt and it broke on the third start after replacement. That is when I found the idler loose. It is a 13mm head on the bolt. It seems this might be something to watch, maybe locktight bolt when replacing belt.

I've pretty much reached the conclusion that the "Bolt" with the 13mm head, Breaking off (fatigue???) is the guilty party in this mystery - NOT the Serpentine belt. That belt was in good condition.



Also, its possible the Bearing on the idler pulley seized up and caused the bolt to snap. Either way, its unacceptable.

 

[WCPoe]

FYI



Don't forget about Geno's Garage. They have the belt, the tensioner pulley and the whole tensioner assy at decent prices.



DAYCO 5081260 - SERPENTINE BELT ('03-'09) DODGE, WITH A/C-Dodge Cummins Diesel Truck Accessories – Geno’s Garage



DAYCO 89094 - TENSIONER PULLEY ('03-'09 5. 9L & 6. 7L) DODGE-Dodge Cummins Diesel Truck Accessories – Geno’s Garage



GATES TENSIONER ASSEMBLY ('03-'09) 5. 9L & 6. 7L-Dodge Cummins Diesel Truck Accessories – Geno’s Garage



(Actually they carry the Mopar, Dayco and Gates belts, each priced a bit different)



And for those who have the, (2003-2004. 5), lift pump mounted on the side of the fuel filter housing they have a replacement for that, (Dodge requires the in tank retrofit).



REPLACEMENT FUEL TRANSFER PUMP ('03-'04. 5) DODGE-Dodge Cummins Diesel Truck Accessories – Geno’s Garage



FYI