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I apologize for the length of this message.
My baby (1990 240 DL automatic wagon w/b230) began having a belt noise many months ago while going through a raining period living in the northeast. I saw no physical damage and chalked it up to the weather. Few months of having these belt noises when it would rain ended when last summer I moved to Southern California. 9 months later I (March 2007) moved once again back to my childhood home of Missouri, smack into the spring storm season and the problems began a new. This time though I ignored the noises a bit since they had not happened in so long and just assumed it was the weather again, until the belt was thrown.
The alternator was bought and installed by my good friendly Volvo mechanic (who lives in PA) some 30K miles ago and is the OEM Bosch Volvo. At first I just replaced the belt and went back along my way but just two days later this new (Gates 7365) belt was violently rejected by the motor, the remains made me believe it was just a DOA belt. After replacing that belt the noises persisted and I began my rabbit hunt that has lead me here today. I have called on many people's help in this department including Roger Scott on the allexperts website, the local Volvo dealership, and my friendly Volvo mechanic in Pennsylvania.
I removed the alternator and had the charging components tested; good. I replaced the bushings on the alternator and power steering mounts. I replaced the adjustment bolt on the alternator that had become worn and adjusted nearly every little bolt/nut/knob or odd looking thing I could find. (which is about the time the Overdrive relay went out and I re-soldered it myself)(and I plan on changing my brake pads Tuesday as they are now making noise). The noise still kept haunting me but now it was more erratic (not only during rain) and oddly it was not damaging either of the two new belts I had bought and installed. I was monitoring the entire thing like a mother must with their first born child in the middle of the night, popping the hood every night when I got home and inspecting the contents. What I discovered was that my alternator pulley was heating up while the crank and fan clutch were not, after about a week of seeing this pattern I caved and decided to replace the alternator.
Getting parts for a 17 year-old Volvo in rural Missouri is no small feat but I ordered one from the local parts store and when I went to pick it up there was no pulley which worried me. As we went to transfer the pulley to the new assembly we discovered that the old Bosch stem was missing it's Woodruff key, I rejoiced in this find and replaced it and headed home with my good old alternator and a frustrating story. No noise for nearly 600+ miles when all of a sudden a few nights ago I heard the dreaded sound, lasting only a few moments when I first started the car late in the night. Then again the next morning and one other time in the mid-day sun when picking up lunch. The belt looks perfectly fine and now I am stumped again. I don't personally have the tools to look to see if this Woodruff is broken or missing now but that is my next/only option at the moment.
If/when I do get around to finding out about the key, if it is missing is there some particular key I should buy (the one I got was a cheapie, not specific for anything)? If it is still intact and in good working condition is there something else I should consider? And finally has anyone else ever heard of this problem occurring?
I am proud to say the old girl turned 178K yesterday and I want/need many more out of her.
Thank You very much in advance- more details can be provided if asked for
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