About the truck
2006 4runner Sport, V6, 203300 miles, new OEM serpentine belt change two years ago.
About me
Off-roading taught me a long time ago to do as much of my own work as I can. The more I know, the better I can trail fix and or diagnose as needed. I rent a garage bay with a lift that is supervised by a master mechanic who looks over my shoulder and keeps me from doing stupid stuff!
The Drama
So 280 miles into a 600 mile road trip without any warning, my dash lit up like a Christmas tree. I immediately pulled over the side of the highway in the middle of nowhere between NW Texas and NE New Mexico and realized I had no power steering or aircon.
Popped the hood to see a mess of shredded belt, oil and what I assumed was coolant over everything. Belt did not break and had not slipped off, but was almost completely gone. ODB reader showed code P0117, no surprise there as it was 97degrees out and I had been driving at highway speeds for two hours.
Pulled out chunks of belt while waiting for the tow truck. Got the truck into the shop and up on a lift. Spent an hour cleaning up the engine enough to determine I had a power steering leak from the pump. Replaced the pump, threaded on the new serpentine belt, checked pulleys and idlers without identifying any issues, refilled power steering fluid, topped off the coolant and cleared codes (P0117). Test drive home went well, no codes and no leaks over night. Normal driving around town for two days with out issues.
Back in to the garage with the intent to replace/upgrade the suspension (still on stock XREAS at 200K without issues!). As soon as I pulled into the bay, oil starts raining down. More engine compartment cleaning to find a fine mist spraying out from the crank shaft. Pulled off the crank shaft front seal and replaced. Back of the crank shaft pulley was wrapped with more of the shredded belt which I assume damaged the front seal. Cleaned oil off of things as best I could, carefully put the belt back on and had the master mechanic verify the belt was threaded correctly. Changed out my differential and transfer case fluids (it was time) so the day wasn't a complete waste and drove her home. No leaks the following morning.
Yesterday I headed BACK to the garage and started the process of replacing and upgrading the suspension. While removing the sway bar up front I noticed that the new belt is now starting to fray very slightly on the engine side, just like the first belt. The good news is that I caught it very early on.
Reading the forums, my plan on Tuesday will be as follows
1) Recheck all of the pulleys and idlers a second time
2) Check the tensioner
3) Replace the thermostat as it may have been damaged with the initial overheating
4) Recheck the torque on the power steering pump and the crank shaft
Questions:
1) Is it worth pulling off the idlers and anything else relatively accessible to rule out more pieces of shredded belt being behind them?
2) What else should I check or consider?
Thoughts and help appreciated!
Images attached show the dash lights, the shredded belt, the fan, old PS pump, old Crankshaft seal, new crankshaft seal. I have not figured out how to label the images.