Just tried to to replace the idler pulley on my '94. The washer, though, seats on the pulley instead of on the bearing...causing the new pulley "not" to turn. I re-installed the old pulley until I can figure this out. While comparing the new with the old part I noticed that the bearing on the old part was just ever so slightly protruding from the pulley. This allowed the washer to seat on the bearing. The bearing on the new pulley is just shy enough that the washer rests on the pulley instead of on the bearing. Any remedies...or just return the new part? Thanks.

 

Thought about it overnight. Could that concave washer be left off when installing an aftermarket pulley? The attachment bolt would then rest directly on the bearing with no contact with the pulley.

 

I guess if it was me I would take it back and compare tolerances with other pulleys. Good Luck!

 

OK...In researching online, I found that it is not a washer, but a "dust cover". This dust cover does not fit aftermarket pulleys and a I found where a Dayco rep posted that the dust cover is not necessary with the sealed bearings that are used in the replacement parts.

 

I guess you lost me, I thought the pulley was binding.

 

It was....binding because the dust cover was pressing against the body of the pulley...instead of pressing on just the bearing portion.

 

Okay gotcha! Glad you have it resolved. Good deal!

 

Yep...it worked. Just installed the new pulley without the "dust cover". Took 5 minutes and fits perfect and works.