RR P38 Idler tensioner pulley 4.6 /4.0 V8

[Hoges]

Finally tracked worrying knock to a shot idler tensioner pulley. Bearing was rattling around in thermoplastic casing. Not good! even Mrs H commented ... only found it by luck when I removed the pulley while replacing the inlet manifold valley gasket etc.

Microcat ( ERR 6439) and other sources (including Gates catalogue part no. 38245) only list full assembly ...incl the tensioner arm. Local prices for assembly vary from $135 -$190...(though I note Atlantic British list same for US $75...such is price we pay downunder for living in a small market!)

Good News is that the offending bearing is replaceable: see http://www.precisionparts.com.au/Pages/ ... ochure.pdf . Part Number is EP027.

Was able to source the pulley locally here in Brisbane for $43 -it's in cast iron rather than thermoplastic.

This part is also applicable to Disco V8

Hope this helps

[p38arover]

Hoges has updated the info on the RRNET thread RangeRovers.net • View topic - Idler Tensioner Pulley as separate Part (http://www.rangerovers.net/forum/viewtopic.php?f=3&t=25471&p=194046#p194046) and out of that we have found that the Dayco 89054 at about US$24 is the right part. Thanks Hoges, if you hadn't started the thread, we wouldn't have looked.

From the Australian Dayco website:

Enter OEM or competitor part number: ERR6439

LAND ROVER part number ERR6439: https://www.aulro.com/afvb/images/imported/2008/07/1074.jpg equivalent part number: 89287 (tensioner) (http://www.dayco.com.au/PartInfo.aspx?P=89287), 89054 (pulley) (http://www.dayco.com.au/PartInfo.aspx?P=89054)

What is odd is that if you click on the numbers on the Dayco site, you get Part No. Not Found. :(

Now to get an Australian price.

https://www.aulro.com/afvb/images/imported/2015/05/1138.jpg

[Scouse]

Is this the same pulley that was subject to a recall early on in the P38 days ?
I thought it was a plastic pulley that was replaced with a metal one.

[p38arover]

No, I think that was the idler pulley. I'll check the TSBs.

Wait, was it this:



Campaign Number: D385
VIN Range: [no data entered]
Serial Range: [no data entered]
Product Info: Vin Range Xa410483 To Ya429903.
Defect Details: Failure Of The Power Steering Pump Pulley May Occur At Low Kilometres As A Result Of Fatigue Cracks. In The Event Of Failure The Serpentine Drive Belt Will Be Subject To Damage Resulting In Loss Of Power Steering, Electrical Charging And Vehicle Cooling

Then there was this:



Land Rover Discovery Series Ii, V8 Vehicles - Campaign D216
Date: 23/06/2000
Supplier Name: Rover Australia Pty Limited
Dealer Contacted : No
Product Make: [no data entered]
Product Model: [no data entered]
Target Number: 0
Model Years From: [no data entered]
Consequences: Failure of pulley will cause drive belt damage which will result in the loss of power assisted steering, electrical charging circuit, air conditioning and cooling system.
Campaign Number: D216
VIN Range: [no data entered]
Serial Range: [no data entered]
Product Info: Vehicles Built Between 27 August 1998 And 3 April 2000. Vin Range Xa200611 To Xa900000; Ya277051 To Xa907212.
Defect Details: The Ace Air Conditioning And Power Steering Fitted To This Model Applies Additional Loading To The Idler Pulley. Failure Of Pulley Will Cause Drive Belt Damage Which Will Result In The Loss Of Power Assisted Steering, Electrical Charging Circuit Etc.

[p38arover]

I forgot to update this thread.

In 2009 I visited the US so I ordered the pulley and had it shipped to another RRNET forum Admin, Carl aka rrtoadhall, as I was visiting him.

When I got home, I opened the packet to find the wrong pulley - right diameter but with only 6 grooves, not 7. Not Carl's fault, mine for not realising it whilst still in the US. It looks like a Dayco 89012 which fits a lot of cars.

Never mind, I'm going back to Seattle this year so I'll get another one shipped to Carl. $13 from Amazon.

But first, I'll check again if it available locally as it is in the Dayco Aust catalogue.

[Rat_RR02]

Finally tracked worrying knock to a shot idler tensioner pulley. Bearing was rattling around in thermoplastic casing. Not good! even Mrs H commented ...
Was able to source the pulley locally here in Brisbane for $43 -it's in cast iron rather than thermoplastic.

This part is also applicable to Disco V8
Hope this helps

Hey there Hoges,
yup, I found the replacement steel/iron pulley too and I have ordered it, which seems the logical thing to me. I dont think the extra rotating mass is really significant and I want reliability.
I want to replace the two Idler pulleys as well. Did you find a source for those here in Aust?

Cheers
Mick

[p38arover]

Never mind, I'm going back to Seattle this year so I'll get another one shipped to Carl. $13 from Amazon.

But first, I'll check again if it available locally as it is in the Dayco Aust catalogue.

I bought two of them in the USA.

[Pierre]

I have just completed changing the bearings in these 2 idlers, after the dreaded whirring set in. 6304 in the large one, and 6203 in the small one. The surfaces were OK - the cost was under $15 for the pair of bearings. Entirely serviceable repair. See a bearing supplier for the correct sealed application.

Pete

[jsp]

they can be replaced? bugger I should have kept my old one after putting in Ron gave me!

[p38arover]

they can be replaced? bugger I should have kept my old one after putting in Ron gave me!

Not in the plastic idler as far as I'm aware. Was Pierre's plastic?

[Pierre]

Not in the plastic idler as far as I'm aware. Was Pierre's plastic?

No, Ron. Both idlers were steel, and I treated them like a 300tdi idler - circlip off, push it out, new one in, replace circlip; and on the smaller one - push it past the stakings, new one in and restake with centre punch.

I'd reckon the plakkie one would be bin fodder, like GM ones.

Pete

[p38arover]

Thanks Pete.

[RFollia]

No, Ron. Both idlers were steel, and I treated them like a 300tdi idler - circlip off, push it out, new one in, replace circlip; and on the smaller one - push it past the stakings, new one in and restake with centre punch.

Pete

Did you have any problems with the stakings? Do they allow to be ground off and restaked in a different place?

As far as the separete pulley goes, I had it delivered from the USA by rockauto

There are 2 metal pulleys available as well for the tensioner sold by rockauto, under the cooling section of the car model.
ACDELCO 36102
GATES 36102
Seem to allow the bearing replacement, avoiding having to buy the complete pulley

My bearings in all pulleys were a bit on the dry side, but there was neither whine nor rumble nor play, so the seal was carefully levered out and new grease pumped in. All smooth again..

Best regards
Robert

[p38arover]

I bought two of them in the USA.

The new one I fitted has gone noisy within 4,000km of installation. 'Tis a good thing I kept the one with 245,000 km on it (it's been cleaned and greased a few times).

[Pierre]

dud bearing pushed out past the original staking easily.

Pete:)

[wayneg]

I just picked up a new tensioner pulley from Auto One. The make was Nuline, part EP027. Its Steel and cost A$36.95inc gst. (The bearing is a 6203 RS)

[p38arover]

One should specify if the pulley is for a GEMS or Thor engine.

[wayneg]

Oh dear, I just read this thread and bought the 027 pulley. It looks ok from a quick glance.

[wayneg]

I fitted the pulley today, no dramas it fits the Thor perfectly. Old pulley bearing was noisy and warn causing a slight wobble. Old pulley was plastic , new steel.

[Hoges]

While refitting the tensioner and idler pulleys last night I noticed that there was a deal of slack and all three bearings were "rattling" - I replaced the original plastic tensioner pulley in 2008 with a steel one -less than 30,000km ago!

The bloke at the bearing supply place today had a couple of different grades of required bearings(1 x 6203 and 2 x 6304) in stock...recommended those with the "C3" designation. Apparently these have larger radial clearances to account for thermal expansion when running constantly at high revs in hot conditions... price was $11 for the 6203 and $22 ea for 6304. Relatively simple job to press out the old and refit the new from the steel pulleys.

While I seemed to have been able to strip the heads off, bag and label parts etc in two - three days with usual domestic interruptions... not so the reassembly. Seems to have taken forever... hopefully I'll have it running tomorrow , or Sunday...

[Scouse]

I forgot to update this thread.

In 2009 I visited the US so I ordered the pulley and had it shipped to another RRNET forum Admin, Carl aka rrtoadhall, as I was visiting him.

When I got home, I opened the packet to find the wrong pulley - right diameter but with only 6 grooves, not 7. Not Carl's fault, mine for not realising it whilst still in the US. It looks like a Dayco 89012 which fits a lot of cars.

Never mind, I'm going back to Seattle this year so I'll get another one shipped to Carl. $13 from Amazon.

But first, I'll check again if it available locally as it is in the Dayco Aust catalogue.Just to update this thread, it seems that Dayco 89054 is now readily available in Australia. I'm ordering a couple from my local auto shop.

[Scouse]

I picked them up yesterday & they're identical to the original LR pulley - plastic with the bearing moulded into place.
$20 each so if they last 20 years like the originals, I'll be happy.

Actually, if the rest of the car lasts 20 more years, I'll be ecstatic!