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SOLVED Replace Idler Pulley

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by awommy, Aug 4, 2015.

  1. awommy

    awommy Junior Member

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    I was attempting to replace the drive belt in my 2004 Prius, but I ended up rounding out the 14mm nut on the idler pulley while attempting to loosen it. I went and bought a replacement 10m x 1.25 flange nut, and a 10m lock washer, per this thread (Idler Pulley Flange Nut | PriusChat), to replace it once I got it off. However, nothing has gotten this thing off. I have tried socket wrenches, Irwin vice grips, and a gator grip socket. My friend took a look at it as well, and we have tried shocking it by heating it with a torch then dumping cool water on it, more vice grips, hammer and chisel, and a dremel. The nut will not budge, nor will it chip or peel away. In the process of using the dremel, we sliced into the threading a bit, and also very slightly into the side of the pulley.

    At this point, the best thing to do is probably to slice off the nut end of the bolt, and replace the whole assembly (pulley, bolt, nut). I am worried, though, that we will take off the old pulley, and find out that we need to replace the entire stud that the pulley is attached to. As the nut will not come off no matter what we try, I'm driving the car as is, with a mangled nut holding the pulley on. Is the stud a valid concern, or is this assembly a pretty straight forward replacement? Do I need to get an OEM replacement? What part number should I look for? Does the replacement come with a nut and a bolt? I was searching for a diagram, or pictures of someone else replacing the whole pulley, but I can't find anything.

    Thank you for your help.
     
    #1 awommy, Aug 4, 2015
  2. JC91006

    JC91006 Senior Member

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    use a longer cheater bar for leverage and it'll come loose without any problems.
     
    #2 JC91006, Aug 4, 2015
  3. Patrick Wong

    Patrick Wong DIY Enthusiast

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    If you purchase the correct original equipment idler pulley, it will come with a replacement stud, washer and nut. So you can destroy the original as necessary to remove it. 16630-21020 is the Toyota part number.
    How to replace engine coolant pump and thermostat | PriusChat

    I am wondering what socket you used which rounded the 14 mm nut? I suggest you throw that socket away and buy a high-quality six-point socket to replace it.

    Also buy a quality 3/8" breaker bar and cut a short length of steel pipe to use over the breaker bar as needed to improve your leverage. I use a ~2 foot length of natural gas pipe for this purpose. It is necessary to employ some judgment and care when using a cheater bar so that you don't damage the hardware involved or your hand and arm, for that matter.
     
    #3 Patrick Wong, Aug 4, 2015
    Last edited: Aug 4, 2015
  4. awommy

    awommy Junior Member

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    I was using a Craftsman six-point 14mm socket on a normal 3/8" ratchet. I did not have or use any type of extender for leverage.
    I have hope that I will be able to swap this out with minimal issues. I appreciate the part number and the link, Patrick.
     
    #4 awommy, Aug 4, 2015
  5. JC91006

    JC91006 Senior Member

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    just find a longer hallow steel pipe to slip over the ratchet, anything will work
     
    #5 JC91006, Aug 4, 2015
  6. Patrick Wong

    Patrick Wong DIY Enthusiast

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    Usually the Craftsman sockets are pretty good. Sorry to hear that caused a problem in this situation.

    Be careful when using a cheater extension on a ratchet wrench because the ratchet mechanism is easier to damage and the ratchet costs more, compared to a breaker bar.
     
    #6 Patrick Wong, Aug 4, 2015
  7. awommy

    awommy Junior Member

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    I realized I never completed this thread. We ended up taking it out completely using a dremel and patience. Bought a replacement pulley, which did come with a stud, and just replaced the whole deal. Thank you for your help.
     
    #7 awommy, Jan 27, 2016
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