funny you mentioned hacking up an allen...

Ive been doing that for about an hour and not getting very far even with new blades...HAHA

Hopefully you are using blades intended for cutting metal. I have had no trouble cutting up Craftsman allen wrenches in the past - maybe some brands are hardened more than Sears though. I last cut one up to get out a motor mount on a 240D.

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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

Additionally, you do not need to remove the fan for this job. The fan blades have different sized spacing on 2 or 3 blades. Find that larger openning, pull the clips positioning the radiator and pull the rad forward a 1/2" or so. Ought to give you enough room to get the hex bit on the roller pulley. Removing the rad cross member and horn bracket will give you even more room to work.

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Terry Allison
N. Calif. & Boca Chica, Panama

09' E320 Bluetec 77k (USA)
09' Hyundai Santa Fe Diesel 48k (S.A.)

Well... since it SUN afternoon and not much else to do I remembered I had a dremel tool. A few cut off discs gave their life but I cut up an 8mm allen wrench taped it up stuck it in a deep socket connected a long extension..

Now I have my tool...YEAH!!!

Busted out my strap wrenches since the belt was not doing much good got it good and tight and with a bit of ebow grease.. Got it out!!

I was concerned about getting that big hex nut out but since the belt was off the water pump I just turned it in the opposite direction while holding the bolt with my new tool and the bolt just came out.

SWEET!!! The pisser is that I have to wait a few days to get the parts from anywhere even the STEALERSHIP... even though I wont go there.

Here are some pics.

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When the melted pulley came off it looks nothing like other ones I have seen on line for sale for my year?

I still have the big shaft and the spring tensioner but the hole for the bushing and pulley are huge.

This is what Im talking about.

???

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I think you lost the bearing

http://catalog.peachparts.com/ShopByVehicle.epc?q=1998-MERCEDES--BENZ-E300&yearid=1998%40%401998&makeid=63%40%40MERCEDES+BENZ%40%40X&modelid=6384%3AFT|6%3AED|814%3AMBC|1572%40%40E300&mode=SS&yearid=1998%40%401998&makeid=63%40%40MERCEDES+BENZ%40%40X&modelid=6384%3AFT|6%3AED|814%3AMBC|1572%40%40E300

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Marty D.

2013 C300 4Matic
1984 BMW 733i
2013 Lincoln MKz

I wish that I would have seen this post earlier. I replaced that pulley last week. Bought it from the dealer for $65

Actually, my wife got the pulley off. Yes. She is something.

You can take the 3 bolts off of the fan,instead of taking off the entire mechanism.

Only thing holding that pulley in is a 6 or 8 mm hex bolt (metric) Pop the clips holding the fan shroud in place. Pull the shroud out, it will get hung up on the bottom, against the fan blades. You just have to fish it out, flash light comes in handy.
3 bolts holding in the fan, I think star bit, can't remember. Then easy access to the pulley.

My pulley was making noise.