There is some inside info you need to understand the "why" here. While in Baja last week my idler pulley came off my 1985 4Runner. The replacement pulley I acquired in Guerro Negro was different in many ways. It came from a Gen3 truck (1990-1994). It did fit without any modification.

This bearing is a repeat offender and does cause problems, eventually. Figured I would post this little bit of tech for everybody.

I was able to pound out both bearings, making the bearing replaceable in both styles of pulley when the bearing takes a crap (this has been debated). The older style pulley has a snap ring retainer, the new pulley does not. The part you would acquire from the dealer when the bearing takes a dump is totally different and the bearing will not be replaceable (I saw the part on Friday). It costs $170 IIRC. When I've replaced the 6204 bearing before it was only a few bucks. I would guess the same for the 6203. Note that there are frequently additional letters after this number, depending on brand. These numbers usually tell if the bearing is not sealed, sealed on one side, or sealed on both sides. You want a bearing sealed on both sides.

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I acquired the replacement pulley from a 1985 4Runner and decided to make a side by next comparison with the newer style pulley. The pulley that was on my truck was the same as the pulley I pulled from Matt's 1985. Should be no surprise as they were both the same model year (although there are some differences). The Baja donor was from a Gen3 truck (1990-1994).

Here is what I've learned.

Old Pulley: The bearings are different, bearing size 6204, ID is 20mm, OD 47mm. It was held in place with a snap ring. This pulley rode on another part that both backspaced the pulley from the motor and filled the gap between the spindle and the bearing (no idea what it's called). You can see the part in the pic. There was also a large washer with a lock washer, and a 19mm nut holding it on. The pulley was a cast part, weighed 12 oz without the bearing (almost twice the newer), and was 64mm in diameter at the belt surface.

Newer Pulley: The bearing size was 6203, ID is 17mm, OD 40mm. The pulley rode on the spindle without an internal spacer. This pulley had a fat washer/spacer front and rear with a 14mm nut and no lock washer. This pulley was a stamped part, weighed 6.5oz, and was 73.6mm diameter at the belt surface.

Pics up at: http://ratstew.home.comcast.net/pulley/

good stuff.

adding to the tech here. if the bearing starts making slight noise you can usually pull the pulley pop the inner seal carefully clean with brake cleaner and repack with hi temp bearing grease. mine was making noise years ago. i did this and no probs since. Id say i probly put 50k of road miles on it since and countless trail hours. ive pulled a couple off trucks at work making noise and they was all exactly like mine. grease gone or hardened providing no lube.

My local dealer said that they get their pulley bearings from NAPA and sent me on my way! <img src="/forums/images/graemlins/lol.gif" alt="" /> So much for genuine Toyota parts, but I guess it pays to be friends with the parts counter folks! <img src="/forums/images/graemlins/smile.gif" alt="" />

I just came back from my dealer. The bearing does not show up on the parts catalog ... I already knew that. You have to purchase the entire pulley. BUT, that bearing is available from Toyota. It has another application and it takes a rather knowledgeable Toyota guy to know this. Fortunately, Dan has been selling Toyota parts for something like 25 years.

So, he stocks the bearing. My price, with tax, was $5.73. I might have bought the bearing cheaper at NAPA, but I like my local dealer and give them my business when ever I can (which is most of the time).

$5.73 is a great price for that bearing...don't think you would get it any cheaper from napa.

i got mine from a bearing supply company (applied technologies, inc.)...they charged me about $9 for the SKF or NSK (don't remember offhand) version.

Wish I wouldv'e had this info when mine went up. Good thing my neighbor is a Toyota Service writer, so
I got it for his discount.

The spacer that you were refering to is a bronze bushing. It is there so when the bearing siezes, the inner race will slip on the outer portion of the bushing. This keeps a catastrophic failure from happening.

Good Stuff by the way.

Actually the spacer is steel. I just hug it from a magnet. Also, the Toyota part number for the bearing that fits the cast pulley (6204) is 90099-10091, list price $7.16. It was an NSK bearing.

That's a really good price for the bearing. Got one from Napa last month and it was nearly $25. IIRC, the bearing on the alternator pulley will work too.

I bought the 6023 RS bearing at NAPA last night and it was around $10 with tax.

Pappy, thanks for the 6023 part number! <img src="/forums/images/graemlins/cheers.gif" alt="" /> NAPA had no cross reference and I would have had to show them the bearing to match it up otherwise. You should put this info in the parts number thread for future reference. By the way how do I remove the newer 6023 bearing
from the pulley?

Not familiar with the 6023 bearing, or the pulley it's in. The two bearings I came across were the 6203 & 6204.

Assuming you transposed the numbers, the bearing I bought from the dealer was the 6204 which is larger than the 6203. In both cases I placed the pulleys on a pair of wood blocks, placed a socket on the backside, and hit the socket with a BFH a few times. Both came out real easy.

With the 6204 you first need to remove the snap ring, but the 6203 did not have one.