Idler pulley tensioner replacement

Look guys we all know shit happens when you're working with rusty bolts. Well while trying to remove my A/C belt I seriously messed up my tensioner pulley. I'm pretty sure my only option is to get it out in 2 broken pieces. So I'm wondering if anyone knows where to get a decent replacement. It doesn't have to be OEM but I'd like it to not be a piece of junk. I've looked but I haven't really found anything.

 

Is the pulley broken, or worn out? Which 2 parts are in pieces?

 

The pully itself is fine I replaced it like... maybe a year ago. It's the tensioner that's shot. The bolt that goes through the pulley is seized into the tensioner.

 

Oh yeah. I think I also have this problem. (except without the bent bolt) I changed my belts about 6 months ago, and when tightening this one to torque spec, the thing just started spinning out and not tightening anymore. Going to be a real pain to try and remove the nut now. Hopefully someone on here has some good suggestions for this sort of stuff

 

Worse case will be taking the bracket off to be able to work at things .

You just need to replace the adjusting bolt maybe the locking bolt

Keep spraying lube tapping with a bar since a hammer won`t fit.

You are going the correct way after all these years I get mixed up .

 

I was able to break the pulley bolt loose and I just cut off the tensioner bolt. Went to toyota dealership and got all 3 pieces for under 10 bucks. Thanks everyone for your help!

 

What did you torque the bolt to last year when you replaced it? Seems like it shouldn't sieze up from rust in just one year.

 

So turns out, as the day continues on, toyota gave me the wrong parts. I went back in and you have to buy a whole kit for like 50 bucks. When I put it on last time I messed up the threads and that's why, coupled with the rust, it wouldn't come off. The problem I'm facing now is the tightening bolt is too long because I believe in the factory they install it the put the engine in the truck. So I might have to cut off about half an inch in order to get it to fit.

 

Can't you slide the pulley part up to make room for the adjuster bolt as you loosen it? Or worst case remove the bracket. I doubt you need to remove the engine to get that bolt out. Give Toyota engineers a little more credit, lol.

 

It can be done I replaced a few of the adjusting bolts .

Without it being right in front of me trying to tell you how would be confusing .

 

I didn't need to remove the engine that would totally be excessive. If you wanted to do it the correct way I believe you would have to remove the AC bracket. From there the tensioner bolt would have enough room to go in. I took the route of cutting about an inch and a half off the end that way it would fit into the hole and not get caught on the frame crossmember thing.

 

Glad I'm not the only one here struggling with this A/C pulley lol, the Idle Pulley Lock Nut on my 1999 was seized in very bad as well I ended stripping like 70-80% a few hours ago and I need to replace my A/C belt ASAP to get the truck running, has this happen to anyone else? I tried using a 14mm bolt extractor but still no luck, should I try to use a dremel to carefully cut around it? Suggestion?