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VW MKIII-A3/B4 TDIs This is a discussion about MKIII-A3/MkIII Jetta/Golf (<99.5) and B4 Passats (96,97) TDI's. Non TDI related postings will be moved or removed.

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Old February 28th, 2015, 08:20   #16
Steve Addy
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$100 to be done with it and it's a one-time, rebuildable expense...worth it!
Couldn't tell you whether it's actually being sold as rebuildable or not. I had considered it a while back but couldn't justify it since I haven't actually had one fail...ever.

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Old February 28th, 2015, 08:30   #17
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This is the first time I've had one fail on me but do vaguely remember the mustang pulley mention years ago and thought it worth while to pursue but really, they are best just to carry a spare or always check it every once in a while.
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Last edited by TDIDaveNH; February 28th, 2015 at 11:07.
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Old February 28th, 2015, 10:03   #18
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I had no problems making the mustang pulley work. To each his own as usual.
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Old February 28th, 2015, 11:28   #19
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Your fabrication skills are above others as well
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Old February 28th, 2015, 12:29   #20
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But what exactly did you do to make it work? Inquiring minds want to know. Did it happen to have a bearing with a 15mm bore or was some adaptation necessary?
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Old February 28th, 2015, 14:15   #21
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I have a collection of various spacers and bushings and found one that fit. Sorry I am vaca at the moment, too far from my shop to be able to show you exactly how I did it.
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Old March 4th, 2015, 10:17   #22
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In playing around with the roller last night, I found that there are two different OEM plastic rollers, something Abacus had mentioned to me recently that I had forgot. Well, in rooting around I happened to have one of the earlier single bearing rollers, (028 145 278 A) started looking at it and realized it had a 17mm hub diameter as well as the same 6203 bearing found in the Gates metal roller. Seems the smaller double bearing roller (028 145 278 E) has the 15mm hub and will not work with the Gates roller. Since the single bearing roller was getting lumpy and noisy, I decided to press it out just for fun, knowing what I'd find but never having actually viewed it before. So like the double bearing roller that is two halves glued together, this one is molded around the bearing.


Here we have the 17mm hub with 19mm hex from roller 028 145 278A on the left with it's corresponding press-fit spacer sleeve and the 15mm hub, 17mm hex from double bearing 6002RS from roller 028 145 278E also with it's press-fit washer spacer on the right.


This turned out to be as easy as you can imagine, no mods necessary as long as you've got the 17mm diameter hub:








And finally, how it all works
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Old March 4th, 2015, 10:19   #23
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Awesome Dave! I knew I didnt have that hard of a time with it
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Old March 4th, 2015, 10:35   #24
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Nice work! Time to head out and round up a couple early single bearing serpentine belt rollers!

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Old March 4th, 2015, 10:43   #25
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It's all about starting with the correct hub. Folks if you have a failed single bearing tensioner, don't toss it out... Save that hub & sleeve!!! Chris, I was wondering how you did that, like what the trick was but there is no trick. For those that have only the 15mm hub, That may still work, but you'll have to swap the bearing out to an oddball 15x40 size and possibly play with the back spacer to make it work. I seem to think that the smaller bearings that are doubled up fail sooner than the big single since the cooling of the two sides that are against each other is non existent. Bearing cooling with the OEM single bearing roller is better and even better still with the metal pulley with the added bonus of replaceability.

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Old March 4th, 2015, 11:07   #26
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Add to the bearing list WBD bearings that use a high temperature grease and have other features.
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Old March 4th, 2015, 12:34   #27
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Keep in coming guys! I'll add this information as soon as possible; including yours 993er.

TDIDaveNH, do you mind if I copy the images to my server as backup and link them into the posts above later today?
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Old March 4th, 2015, 12:39   #28
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Quote:
Originally Posted by TDIDaveNH View Post
It's all about starting with the correct hub. Folks if you have a failed single bearing tensioner, don't toss it out... Save that hub & sleeve!!! Chris, I was wondering how you did that, like what the trick was but there is no trick. For those that have only the 15mm hub, That may still work, but you'll have to swap the bearing out to an oddball 15x40 size and possibly play with the back spacer to make it work. I seem to think that the smaller bearings that are doubled up fail sooner than the big single since the cooling of the two sides that are against each other is non existent. Bearing cooling with the OEM single bearing roller is better and even better still with the metal pulley with the added bonus of replaceability.

Aside from cooling, the larger bearing should have a higher load rating too so I'd imagine that especially with the vibrations in the TDI that this would help it last longer.
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Old March 4th, 2015, 12:39   #29
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Keep in coming guys! I'll add this information as soon as possible; including yours 993er.
The WAI Global site gave me a temporary user name and password some time ago so that I could download all of their catalogs.

I have the WBD bearing catalog in PDF but could not attach it here. It does list your bearing sizes and countless others.
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Old March 4th, 2015, 12:43   #30
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The WAI Global site gave me a temporary user name and password some time ago so that I could download all of their catalogs.

I have the WBD bearing catalog in PDF but could not attach it here. It does list your bearing sizes and countless others.
Would you mind emailing it to me?
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