Difference between revisions of "NG 900/9-3 Idler Pulleys"
(Created page with '==Overview== The serpentine belt, idler and tensioner pulleys should be inspected every service interval and in theory, replaced every 60k miles, but a pulley bearing often fails…') |
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==Overview== | ==Overview== | ||
The serpentine belt, idler and tensioner pulleys should be inspected every service interval and in theory, replaced every 60k miles, but a pulley bearing often fails earlier. Cost of replacing two pulleys and the belt can be $200-300 for parts and labor plus towing. Alternatives include replacement as preventive maintenance (about $100 for a new belt and two pulleys), the short belt conversion ($60-70 for one pulley and the belt), and aluminum pulleys with replacable bearings. Repacking the pulley bearings is also possible. | The serpentine belt, idler and tensioner pulleys should be inspected every service interval and in theory, replaced every 60k miles, but a pulley bearing often fails earlier. Cost of replacing two pulleys and the belt can be $200-300 for parts and labor plus towing. Alternatives include replacement as preventive maintenance (about $100 for a new belt and two pulleys), the short belt conversion ($60-70 for one pulley and the belt), and aluminum pulleys with replacable bearings. Repacking the pulley bearings is also possible. | ||
| − | + | [[File:900_9-3_Idler_1.jpg|thumb|none|Belt and Pulleys]] | |
===Short Belt=== | ===Short Belt=== | ||
After the short belt conversion, using the Saab oem upper idler pulley, lower idler pulley bypassed, using Michel Briand's web site with instructions and pics: Short Belt Mod | After the short belt conversion, using the Saab oem upper idler pulley, lower idler pulley bypassed, using Michel Briand's web site with instructions and pics: Short Belt Mod | ||
This is not a complete fix, because the remaining upper idler is still the one most likely to fail. | This is not a complete fix, because the remaining upper idler is still the one most likely to fail. | ||
| + | [[File:900_9-3_Idler_5.jpg|thumb|none|Short Belt]] | ||
===Aluminum Pulley=== | ===Aluminum Pulley=== | ||
Short belt with aluminum pulley, oversized by about 10 mm. First version required machining to make it fit. An exact fit is now available, with a standard size 2603 replaceable bearing from Wazee Pulleys | Short belt with aluminum pulley, oversized by about 10 mm. First version required machining to make it fit. An exact fit is now available, with a standard size 2603 replaceable bearing from Wazee Pulleys | ||
| + | [[File:900_9-3_Idler_6.jpg|thumb|none|Short Belt]] | ||
===Aluminum Idler - Closeup=== | ===Aluminum Idler - Closeup=== | ||
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Steel washer, about 15-mm OD | Steel washer, about 15-mm OD | ||
Bolt, M8x125, Saab stock | Bolt, M8x125, Saab stock | ||
| + | [[File:900_9-3_Idler_4.jpg|thumb|none|Aluminum Idler]] | ||
===Short Belt Length=== | ===Short Belt Length=== | ||
The normally recommended 97-inch "short" belt is a little long on my car, the line indicating correct tensioner arm position is just outside the limit marks. A slightly shorter belt like the Goodyear Gatorback 96.75" (2455mm) is a better fit. | The normally recommended 97-inch "short" belt is a little long on my car, the line indicating correct tensioner arm position is just outside the limit marks. A slightly shorter belt like the Goodyear Gatorback 96.75" (2455mm) is a better fit. | ||
| + | [[File:900_9-3_Idler_7.jpg|thumb|none|Tensioner Arm Position]] | ||
===OEM Upper Idler=== | ===OEM Upper Idler=== | ||
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Bearing, 44-mm OD, 8-mm bore | Bearing, 44-mm OD, 8-mm bore | ||
Bolt, M8x125, 13-mm head, 35-mm length, w. 5-mm lead and floating washer | Bolt, M8x125, 13-mm head, 35-mm length, w. 5-mm lead and floating washer | ||
| + | [[File:900_9-3_Idler_8.jpg|thumb|none|Upper Idler]] | ||
===Lower Idler=== | ===Lower Idler=== | ||
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2603 bearing, 40-mm OD, 17-mm bore | 2603 bearing, 40-mm OD, 17-mm bore | ||
Bolt, M8x125, 13-mm head, 25-mm length w. two retaining washers used to center bolt (sold as a kit) | Bolt, M8x125, 13-mm head, 25-mm length w. two retaining washers used to center bolt (sold as a kit) | ||
| + | [[File:900_9-3_Idler_2.jpg|thumb|none|Lower Idler]] | ||
===Tensioner Pulley=== | ===Tensioner Pulley=== | ||
| Line 36: | Line 42: | ||
2603 bearing, 40-mm OD, 17-mm bore | 2603 bearing, 40-mm OD, 17-mm bore | ||
Bolt, 22-mm head, 8-mm shaft, T40, 22-mm long w. one retaining washer, sold as a kit. New replacement kit shown on the left. | Bolt, 22-mm head, 8-mm shaft, T40, 22-mm long w. one retaining washer, sold as a kit. New replacement kit shown on the left. | ||
| + | [[File:900_9-3_Idler_3.jpg|thumb|none|Tensioner Pulley]] | ||
===Part Numbers=== | ===Part Numbers=== | ||
Revision as of 13:12, 15 November 2009
Contents
Overview
The serpentine belt, idler and tensioner pulleys should be inspected every service interval and in theory, replaced every 60k miles, but a pulley bearing often fails earlier. Cost of replacing two pulleys and the belt can be $200-300 for parts and labor plus towing. Alternatives include replacement as preventive maintenance (about $100 for a new belt and two pulleys), the short belt conversion ($60-70 for one pulley and the belt), and aluminum pulleys with replacable bearings. Repacking the pulley bearings is also possible.
Short Belt
After the short belt conversion, using the Saab oem upper idler pulley, lower idler pulley bypassed, using Michel Briand's web site with instructions and pics: Short Belt Mod This is not a complete fix, because the remaining upper idler is still the one most likely to fail.
Aluminum Pulley
Short belt with aluminum pulley, oversized by about 10 mm. First version required machining to make it fit. An exact fit is now available, with a standard size 2603 replaceable bearing from Wazee Pulleys
Aluminum Idler - Closeup
74-mm diameter x 25 mm wide 2603 bearing, 40-mm OD, 17-mm ID Bearing insert, 17-mm OD, 10-mm ID Steel washer, about 15-mm OD Bolt, M8x125, Saab stock
Short Belt Length
The normally recommended 97-inch "short" belt is a little long on my car, the line indicating correct tensioner arm position is just outside the limit marks. A slightly shorter belt like the Goodyear Gatorback 96.75" (2455mm) is a better fit.
OEM Upper Idler
Grooved upper idler pulley, plastic, Saab 64-mm diameter x 24-mm wide Bearing, 44-mm OD, 8-mm bore Bolt, M8x125, 13-mm head, 35-mm length, w. 5-mm lead and floating washer
Lower Idler
Smooth lower idler pulley, plastic, Dayco 80-mm diameter x 24-mm wide 2603 bearing, 40-mm OD, 17-mm bore Bolt, M8x125, 13-mm head, 25-mm length w. two retaining washers used to center bolt (sold as a kit)
Tensioner Pulley
Smooth tensioner pulley, metal, Saab 90-mm diameter x 24-mm wide 2603 bearing, 40-mm OD, 17-mm bore Bolt, 22-mm head, 8-mm shaft, T40, 22-mm long w. one retaining washer, sold as a kit. New replacement kit shown on the left.
Part Numbers
- Long (stock) Belt
- Saab # 4904728 - eEuroparts.com
- Dayco # 5061038 (103.25 inches) - AdvanceAuto
- Short Belt
- Dayco # 5060970 (~97 inches) - AdvanceAuto
- Goodyear # 4060967 (96.75) - AdvanceAuto
- Upper Idler
- Saab # 4356127, plasic pulley - eEuroparts.com
- Saab # 7978216, hex bolt - Saab Dealer
- Aluminum pulley - www.wazeepulleys.com
- Saab # 4356127, plasic pulley - eEuroparts.com
- Lower Idler Kit
- Saab # 4960290 (torx bolt & washer, 94-mid/97) - eEuroparts.com
- Saab # 4752960 (hex bolt, 2 washers, mid/97-98) - eEuroparts.com
- Tensioner Kit
- Saab # 5172184 (w. washer and bolt) - eEuroparts.com
