Cracked off the the lip of the power steering pulley. Replacement pulley?

[beewstew]

Like an idiot, I tried to use a screwdriver to pry the accessory belt onto the power steering pulley. I cracked off the lip, which I assume will shred the belt over time.

New PS pumps start at $200 - has anyone had luck just replacing the pulley? I realize this is a bizarre edge case and I should just go to the junkyard...

Also, the suggested procedure for this belt install is to relax the tensioner with a t60 star bit in the tensioner housing, but a 1/2" T60 socket + 1/2 rachet is too wide for the gap between the 2.5 engine and the firewall. There must be a trick?

Tried to pry on the PS pump pulley and cracked off the shoulder. Oof!

12mm wrench grabs the t60 bit nicely, but the wrench runs onto the timing cover when I try to relax the belt tensioner.

[Blacklab467]

That’s the method I use for the tensioner, it’s a little dirty but it does work. The serpentine belt should last for awhile with that pulley while you source a replacement, I’d just grab one from the auto wreckers.

[cn90]

- I use the Serp Belt Tool (Harbor Freight or online ebay etc.), it has a flat profile and fits in that tight space.
- Not sure if it is safe to run it that way. If the Serp belt ever comes loose, it may get sucked into the timing belt comparment --->
Good Bye engine.
- Idk if the pulley itself can be replaced? Has anyone tried? I am curious.
- Or get a used PS Pump from junk yard from a low-mileage car.

NOTE: diameters of the pulley are different up-to-2004 vs 2005-2009 years. Verify before buying.

[jonesg]

I'd clean the sharp edges up and run it.

[vtl]

Get a used pump. Pulley replacement is not worth your time.

[abscate]

I'd clean the sharp edges up and run it.

^^^

This.

Some nice work with file and then even a bit of JB weld if you feel industrious.

The ABN tool from the jungle makes serp belt replacement easy as pie, or 3.1415926535……

[beewstew]

Sanded the cracked edges smooth and hoped for the best. So far, 40 miles with no broken belt.

[XC70Rider]

I cracked the PS pulley 5 years ago. Down in the southern states P2s are rare so no luck finding one in the salvage yards. To avoid the hassle of replacing that pulley I got a rebuilt PS pump from FCPEURO. Been running fine and has a lifetime warranty.