Hey folks... did a search but nothing was coming up for hat i needed to know.

Basically was driving yesterday and heard a brief griding noise about 2000 or 2500 in 5th quickly followed by two thumps. there was no time to check what was wrong.

Then lost power steering etc. On checking the idler pulley bracket area broke off. Also, the AC compressor pulley separated from the pully clutch face area.

Now my question bears on if it's the compressor seizing or is it just a pulley fatigue. the rest of the pulley is spinning freely with no problem no noise whatsoever. But the armature on the shaft itself spins free half the rotation then there is slight resistance... not enough to seize more in the same way when you turn the crankshaft on the engine it has a slight resistance for a turn then it will turn a little easier (grasping at straws here)

Now is that resistance normal? (piston mmovement or something... I am not sure) or is it that i really have to get another compressor? I was preparing to get a new coil and rotor etc to replace but thought I should find out before.

I have never seen a pulley on a compressor do this before... ever. Mind you it's a 2001 EVO 7 so i dunno if perhaps the clutch just wore out the face till the welded portion of the pulley gave way

 

Damn!

Well, a couple of things.

1. It's a compressor, so obviously, there will be some compression in the rotation. If you can free spin it at all though, I'd have to say that it's free enough where it wouldn't have caused that kind of failure.

2. Do you use your A/C? Might just be worth ditching if not, as the system could be just getting worn from not having the various fluids being circulated.

3. I would probably check your other accessory pulleys. The first thing that came to mind here was belt tension, though if I'm honest... I think that's a stretch, and I'd probably go more with FOD than anything.

It probably isn't going to hurt to replace just the pulley, and it's a hell of a lot easier than doing the whole compressor... being that it isn't a critical system, no big if it breaks again. Aside from losing PS, and of course the possibility of a flying chunk of metal near your oil pan?

 

Yes I do use the a/c mostly. Actually it was on when it happened. The initial thing was a metal to metal grind sound for about a second. then a "thump" and a nasty sorta knocking noise for about half a second (assume it's the pulley that broke loose) and then followed by the idler pulley breaking off.

I checked everything. All pulleys are good. the serpentine tensioner was brand new and changed Nov 2011. no binding on the power steering or even the idler or alternator... nothing.


honestly the Power steering tend to come in handy here. small roads and tight corners... so i'd rather keep everything but just not sure. had a friend who does a/c repair just check it and he is of the opinion the compressor internals are seized, but I don't get how it could break a pulley when it still spins ok.

I was leaning on the strange possibility that the clutch on the ac probably was slipping and overheated the pulley face till it got worn and fatige broke. (again grasping at straws)

It's just something as I said I never say before. Still considering to change the pulley for now and see.

 

It's cheaper to just buy a new compressor than mess with the pulley. Unless you buy used parts, I don't think anyone makes a clutch kit for this model apart from Mitsubishi, and theres is a few hundred bucks. You can regularly find brand new and good quality complete compressor and clutch assemblies on ebay for ~150-200.

 

looks like I have to go that route. But may have to go the used route because of the cost incurred landed in trinidad and tobago. That $100 compressor would probably cost near $1500 TTD landed due to customs...

Have a friend who sells evo parts in trinidad and he should have some used ones in stock

 

Ouch, that sucks

 

Just to update:

The pulley broke due to the AC clutch slipping and grinding through the 4 spokes on the pulley. Now my compressor never had a washer for the free air apace in between the pulley and clutch.

Had my collegue who runs an AC repair shop come check the compressor and it is actually fine: shaft spins freely. So got a used pulley and clutch and new coil. Also replaced the bracket that the idler pulley broke off from and found the bolt used to hold the pulley in was half inch too short...

Anyway, parts should be here soon so it'll be up and running again.