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Broken pulley bolt

Savir

By Savir
in 986 Series (Boxster, Boxster S)

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Savir Member

Savir

Posted
Posted

2001 Boxster S, 6-speed. I'm hoping someone could help since I am at a total loss. The bolt holding the lower idler pulley has broken off four separate times. Each time it happened without any advance notice, i.e. no weird noises, vibrations, etc.

The prior time it happened I noticed that the alternator pulley (the freewheeling type) appeared to have "seized", so I replaced it. Everything had been working normally for while after that, so I thought that the seized alternator pulley had caused undue stress on the system causing the idler pulley to snap. Unfortunately, the bolt broke again.

The two idler pulleys have been replaced, so I don't believe that they are causing the problem. I have manually checked all of the other pulleys, and they don't seem to have any abnormal play.

The only other thing I think could have caused the problem is the tensioner. But I would think that if the tensioner loss tension that the belt would thus become loose and cause a loss of stress on the system. In other words, less stress, less chance that the bolt would break.

Has anybody run across this problem before? Any suggestions as to what could be causing the bolt to break?

Any help will be greatly appreciated.

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