Okay, this is just a bitch post. Plain and simple.
I just can't fathom the design choice used on the 2005 2.6L engine. They may use the same crankshaft pulley design on other models, but I'm not a mechanic (see other posts if you need proof) and not well versed in the different model designs.
Karen called the night before saying that she lost her power steering and smelt burning rubber from under the hood. I figured that it was just an old, stretched serpentine belt. She had a dead battery a few days before, so I figured that if it's been slipping for a while she may not be getting a full charge from the alternator.
She picked up a new belt and I drove her car down to our place to replace it. The trip was uneventful with no problems with the power steering or brakes. Watching the belt bounce from side to side while the engine was running caused me to consider that there must be something else going on – even a loose belt doesn't bounce like that.
Got the old one out and threading the new one on I discovered that the crankshaft pulley had no serrations – the raised groves like all the other pulleys. Looking further down I found out why. The outside ring of the pulley was completely separated from the inner ring. They are connected with just a pressure fitted rubber ring.
I don't know if the engine got too hot and melted the rubber, or if the rubber just gave under pressure/use. Either way… what the heck? We went to the local aftermarket part shop and they don't carry it – it a dealer only part. You ready for this? $300 later… we get a new pulley.
Now.. going to the dealer, I'm thinking they will have to order one in.. it'll take a few days… but nope. The parts guy just turned from the register and grabbed one from the shelf – not 3 feet from the front counter. Makes me think these things are popular items. Now, this kinda solidifies it in my mind. What is the purpose of the design? Really? Perhaps it's to cushion vibrations from the engine to the compressor and the alternator and other parts… no…. wait…. the belt would do that. Okay… so maybe it's a safety linkage. The gear will break before damage is done to the other components.. no wait… again the belt would snap before that happens.
Okay. So.. all I am left with is cash grab. What else could it be? Even the replacement part is manufactured the same – it isn't a solid piece of metal, so even this new one will break the same way again. What is the reason? Anyone know, please add a comment. I don't like thinking that after market OEM sales are designed into the vehicles we drive, but this one seems kinda blatant to me. I'd like to be wrong.
Oh. One last complaint. After replacing the pulley and threading on a new belt, I used the tensioner arm like I'm supposed to – socket into the 3/4 drive and pull back to release tension. The housing snapped. Now, I'd like to think I am just too strong and I pulled too hard, but I am a programmer who sits behind a desk all day – so, that's not even likely. It's just another defect – not one by design (I hope) just crappy workmanship/quality control, whatever. Still, a flaw that would be charged for if it happened in the garage. They would charge for a new tensioner.
Bitch, bitch, bitch. There. I feel much better. 
