Weird.
The impeller may be an interference fit and could loosen when hot which could explain why the problem was intermittent.
It would be interesting, if you are able, to clamp the pulley side in a vice and using a screwdriver in the impeller trying to see if it would rotate.Just a thought.
I was rather expecting you to say that the impeller blades where corroded away!
Anyway it is sorted and the heads good.
