Alternator Pulley - broken twice

[Fraser]

My bongo broke down whilst on holiday in Normandy 2 weeks ago. I was driving along, there was a bang and the battery and sediment warning lights came on. Pulled over straight away as the temperature was starting to rise alarmingly. Recovery came and took it to a local garage and it turned out the pulley that drives the fan belts from the alternator had broken and come loose (it was still attached to the alternator but loose and wobbly). Anyway, I ordered a new alternator and fan belt through my European Breakdown which the French mechanics fitted. Drove away howver the lights kept coming on - not all the time but just when accelerating hard or going up hills and this was accompanied by a ratling noise. Returned to the garage and it turned out the same thing had happened - the new pully was broken and had come loose in the same way as the first!

The breakdown company paid to get the Bongo repatriated and its now with my local mechanic back in London who is flumoxed as to why the same thing would have happened twice. He is currently trying to source a new pully for the alternator in order to avoid having to buy yet another alternator.

I have done a search but cant find any example of this problem recurring or likely causes. Could it be that there is an underlying problem that has caused this to happen twice? Or perhaps the first time was just due to general wear and tear and the second time was due to the French mechanics, unfamiliar with the vehicle, overtightened the fan belt or doing something else wrong whilst fitting the parts.

If anyone has any thoughts I would appreciate hearing them.

If anyone knows where I can get a pulley on its own that would also be appreciated. I will phone round the usual places.

Fraser

[francophile1947]

That is weird!!!
I'd never heard of that happening and now you are the second within a few months - see http://www.igmaynard.co.uk/bongo/forum/ ... ey#p198572

[mikeonb4c]

I seem to recall a couple of previous incidents of this on here, but never twice as far as I can recall. It's hard to believe overtightening the belt has done it as you'd think we'd have heard of more broken pulleys (I'm not convinced that overtightening belts is just a rare happening). One other possibility is cheap/low quality pulleys and/or an unapproved type being fitted?

Dandywarhol would be a good person to comment on this one

[Fraser]

Thanks. My breakdown company have now got the supplier of the replacement alternator to send out a new pulley free of charge so at least I have the part.

Still doesnt explain the cause of the problem....

[You've Been Bongod]

phone mike @ wheelquick on 01942217800 and ask him as he knows bongo's inside out

[Fraser]

Turns out that the company that supplied the alternator supplied two new fan belts with it but they were the wrong size belts. They were slightly too small. The french mechanics didnt spot this and fitted them anyway. The increased pressure must have snapped the pulley.

[You've Been Bongod]

at least you have got to the bottom of this matter and your bongo has not sustained any damage

[mikeonb4c]

Turns out that the company that supplied the alternator supplied two new fan belts with it but they were the wrong size belts. They were slightly too small. The french mechanics didnt spot this and fitted them anyway. The increased pressure must have snapped the pulley.

Hmmm - so who pays

Glad the cause has been traced anyway!!

[Fraser]

Hmmm - so who pays

... yeah I need to sort that out !For now I'm just glad its fixed.