So I have had an issue with the bearings on one of my pulleys. I figured I would go ahead and replace the upper idler pulley because it was the cheapest of the two. 60 for the upper and 150 for the lower. Well it turns put the upper was just fine, and its the lower tensioner pulley making all the noise.
I decided I was going to use my old upper as my new lower.
I examened the lower and noticed on the back side, it has a lip to keep the pulley pulled off the tensioner bracket. I found a washer that was the same thickness of that lip and threw it behind the old/new replacement and that solved the issue of running into the tensioner bracket. The upper pulley is a little bit larger in diameter, but the belt length isn't changing so that doesn't matter. Luckily enough on our cars, mits gave us plenty of tightening and loosening adjustment on this pulley.
I must say, if you ever need to replace the lower pulley, save yourself the money and just buy the upper and add a washer or two to match the lip that keeps the pulley off the tensioning bracket. Much cheaper solution.
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