Idler Pulley Mismatch

[CB-Rubicon]

Hi everyone, I’m hoping someone can help me identify a weird part discrepancy on my 2004 Jeep Wrangler Rubicon (4.0L with AC).
I recently ordered a 3-Piece Serpentine Belt Drive Component Kit to fix some engine noise. While the belt and tensioner installed fine, the new idler pulley does not fit. The diameter of the mounting bolt hole on my original part is larger than the center hole on the replacement pulley.
Extreme Terrain support was unable to explain the why this would be the case. Has anyone encountered a 2004 Rubicon with a larger idler pulley bolt mount, or is it possible I have a non-standard bracket or some kind of variation?

Any insights on the correct part number or why this might be different would be greatly appreciated!

I have attached and image of the two parts next to each other. Obviously the original is on the right and the new part is on the left.

 

[speeding_infraction]

Just checking, do you still have the bolt for the idler pulley?

 

[CB-Rubicon]

I still have the original bolt yes. Its actually not the bolt that seems off as much as the piece that the bolt mounts onto from behind.

 

[JKP]

This is the Litens OEM:

 

[CB-Rubicon]

This is the Litens OEM:
View attachment 664566

Could you tell me how you looked this up? Im not seeing it right away on Rock Auto

 

[CB-Rubicon]

New issue. After putting the Serpentine belt back on to move the car I am noticing this wheel seems to be wobbling a bit. I think this is the Power Steering Pump but I am not certain. I am also seeing fluid leaking underneath the car in this area. Could I have caused this by replacing the tensioner pulley?

 

[jeepguy03]

Replacing the idler pulley wouldn't have caused this, but the power steering pulley wobbling and fluid leaking on the ground could mean your power steering pump is on its way out. With the engine off, can you move that power steering pulley back and forth? Is there play in that shaft for the pump that the pulley mounts on? Can you see where the fluid is leaking from?

 

[JKP]

Could you tell me how you looked this up? Im not seeing it right away on Rock Auto

It's under Belt Drive.

 

[Hacker412]

Amazon has these for sale.. ultra low quality and price .......

 

[CB-Rubicon]

Replacing the idler pulley wouldn't have caused this, but the power steering pulley wobbling and fluid leaking on the ground could mean your power steering pump is on its way out. With the engine off, can you move that power steering pulley back and forth? Is there play in that shaft for the pump that the pulley mounts on? Can you see where the fluid is leaking from?

I am not able to move the pulley back and forth by hand. From what I can tell I dont think there is play in the shaft for the pump either. When its running it appears to wobble slightly for a bit and then it almost skips into place and seems to run smoothly for a while and then back to wobble.
I am also not able to pinpoint exactly where the fluid is leaking from but it does seem to be right around the underside of the power steering pump.

 

[CB-Rubicon]

Amazon has these for sale.. ultra low quality and price ....... View attachment 664756

oof good to know!

 

[CB-Rubicon]

I think this might be out of my depth in terms of repair. Will probably take it into a shop tomorrow morning.

 

[Unique Username]

You can always pick up a couple bearings for $10 and press them into the OEM pulley. Seems cheap and keeps the OEM idler in the equation. You could use a C clamp or vise to replace them, they are not in that hard.

 

[jeepguy03]

I think this might be out of my depth in terms of repair. Will probably take it into a shop tomorrow morning.

I get it, but definitely watch a youtube video on a DIY for this repair. I've replaced several power steering pumps on 4.0L engines and if you have a couple wrenches and a socket set you can do it pretty easily. Sometimes you can even find pumps that come with the pulley already pressed on, so in that case it is loosen the belt, 3 bolts holding it to the intake manifold, 2 lines to connect, fill it with fluid, cycle the steering back and forth, and you are done.