Mechanical fan idler pulley replacement
I can't be the only one to have a bad bearing in the idler for the mechanical fan. Of course, both the idler and the pulley are long since discontinued.
I came up with a solution after a lot of research.
The original 4 groove pulley is 64mm. There are no pulleys made by anyone that are smaller than 70mm. 70 will hit the body of the tensioner.
I bought a 6 groove, 63.5 mm pulley. Gates 38082. Here are the modifications needed to make it work.
The lip on the inside of the pulley (either side, it doesn't matter) needs to be made a bit smaller. I used a grinding wheel gently. See attached photo for size of lip needed.
You also need to shim the pulley so that the belt can ride in proper alignment on the inside 4 ribs. I used 2 5/8" machine bushings that I got from my local hardware store. 1 14 gauge, 1 18 gauge. See photo. Then just bolt it together with the original bolt and washer.
See photos for what you end up with. Works like a champ!