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I'm working on a 1993 244, new to a friend. Two (I think unrelated) questions: 1) should the alternator shaft have a key? 2) could a rough pulley be wearing out belts? Volvo alternator, Volvo belts. All 3 alternator bushings are good; belt alignment is good. Belts match (part #s), looked good, are adjusted correctly.
History: Drove a little. Belts squealed, mostly under load. Brought back to shop. Belts seemed a little lose, adjusted. Applied belt dressing. Drove 20 miles, still squealed. Returned to shop. One belt gone (no pieces anywhere), the other shredded at edges. Much belt residue on alternator pivot. Replaced with matching used Volvo belts. Drove 30 miles, still squealing. Back at shop: belts frayed along edges, more residue.
Removed alternator. 2-part pulley (don't remember seeing one before). Pulley faces are badly pitted/ corroded/ dirty. Removed pulley - no key. Pulled pulleys off 2 spare alternators - no keys.
1) 240 alternators aren't supposed to have keys? Even though there are matching slots in the shaft and pulley. Or have they been lost when the pulleys were replaced?
1a) 2-part pulleys?
2) I think the belts are being eaten up by the roughness on the pulley. I'd thought the squeal was the belt slipping on the alternator pulley but that would have smoother them down some. The pulley faces look like they've been on a car that sat for years - and the rust melded with the pulley metal. The car did sit for 1.5 years but my driver sat for 4 and the pulley faces are fine.
Maybe the car was driven through salt and mud before it was parked. But the rest of the underneath is clean and the other 3 pulleys are shiny and functional.
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240 drivers / parts cars - JH, Ohio
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