Well that really sucked! Got almost to Olympia and the bolt that holds the water pump pulley on the shaft loosened and fell out. This allowed the pulley to cock a few degrees sideways and the serpentine belt to run up onto the back edge of the crank pulley - shredding the belt.

The worst part is that the shaft and the hole in the pulley are tapered so that the bolt in the center of the shaft "wedges" the pulley onto the shaft. The wobble from the pulley being cocked sideways wallowed out the tapered hole in the pulley so that it no longer fit tightly onto the shaft.

So after towing it home on Friday I rebuilt the pulley by welding a thick grade eight 9/16" washer on the backside, and using a dremel to grind the hole out to fit exactly over the small end of the shaft. Then I welded another washer on the front side with an 8mm hole in it (the size of the securing bolt). I stuffed a couple of pieces cut from the end of a tape measure tape into the hole in the pulley as shims between the shaft and the hole in the pulley. I then used the securing bolt to force the pulley the rest of the way onto the shaft. Lastly I removed the bolt, coated it generously with some red locktite, and cinched it down nice and tight. Seems nice and secure now with no wobble and the belt is tracking nice and true.

Hopefully this repair will be permanent. Trying to find a replacement pulley may be very nearly impossible...

So, FTE, looks like we're back to our plan of getting together December 10th.

Sorry about your trouble, see you on the 10th.

Just found the post 10 years later on the 4.3L diesel. How did it go and is it still running?