Tension Pulley Burned Into Block
 

I have a 2004 with the 5.4L 3v, on my way home from work I heard my tension pulley starting to go, as I was almost home from traveling maybe 4 miles from work to home my engine started misfiring and my engine light started blinking, but I was able to make it home 10 second after that. When I took off the tension bar the pulley wasn't even attached to it at all, infact the bolt that held on the pulley was burned halfway through. When I looked at the pulley it was like engraved to my block, so I pulled it out and noticed a little oil came out, I got a mirror and took a better look, the pulley actually burned its way through the block and it looks as though it went into the cylinder head. I'm pretty sure I can see the piston but I don't have that great of a view. My question is, did it actually burn into my cylinder head or another part of my engine? I am pretty sure so since it is in that location and a little oil came out when I pulled the pulley off. If anyone needs pictures I can go out and take pictures. But has anyone ever heard of this? I mean the truck was running great before this, no noises nothing and I didn't take any damages or nothing anytime before this.

wow, i have never heard of this before, take some pictures and lets see if we cant figure out what your looking at but it does not sound good at all man

on my way home from work I heard my tension pulley starting to go...Pull over

I've had plenty of trucks before and I was about less than 2 miles from home when it sounded I heard a low volume noise from the tension pulley. Its not the first time I've ran into a worn out pulley but less than 2 miles is no reason to worry, I've never seen this. I'll get pictures within the hour and show the damages.

Here are the pictures, sorry for the low resolution, my camera won't fit in the space I had, I won't have better pictures until I get the fan and fan guard out of there first.

holy hell!!!! im not any help about the damage but my eyes are telling me thats not good... but im sure guys on here can help you out, good luck

Damn! Out def. looks like It's been wearing in A LOT more then 2 miles. Good luck with it. Ooof

Definitely been wearing a long time for that to happen.

LOL, You didn't burn a hole through your block or anything like that. That would be your timing cover. To be able to see your piston you would of had to burn through your block, through the water jacket (read lots of coolant everywhere), then through the cylinder wall to get to the piston.

I'm very picky about my vehicles so if it did poke a hole through the timing cover I'd replace the timing chain cover, the tensioners and phasers while I was in there. if i wasn't a picky person I'd clean the area really good with brake cleaner, then make sure its completely dry before smearing a good layer of silicone over the problem area.

To Tbuhlinger... please be the picky guy. Thank you

WOW
 

that's really something . I've seen where the tensioner bearings get weak and
the tensioner will wobble and make allot of noise . slipping belt etc. yours must have gone quick . the soft metal cover was easily eaten into .

good luck w/ your project .