Alternator pulley/bearing failure caused by water contamination on crankshaft pulley

This fault is found on Ford Transits with 2.2TDCi engines from 2006 to 2012 (Alternator Part No. AEK2977) A known fault exists which can result in a charging fault and/or noise from the drive belt system. The fault occurs due to water and dirt contaminating the crankshaft pulley and causing it to fail. This results in excessive vibration within the drive belt system resulting in premature failure of the alternator pulley. The image shows contamination and failure of the alternator.

If the vehicle has this fault, inspect the drive belt system and crankshaft pulley. It is recommended that the crankshaft pulley, power steering drive belt and alternator drive belt be replaced.

It is recommended that a splash guard is fitted to avoid this failure occurring again. The fault will reoccur again if the above components are not replaced and a splash guard is not installed.