Afraid of the answer.....

[Qmulus]

It looks to me like the clutch on the alternator spun off somehow. Weird... Does the alternator still spin? How do the idlers feel? How about the water pump? Check them for smoothness and any play.

As for the coolant fitting, I found that brass PEX crimp plumbing fittings work well and have sizes that work great. Cheap too. There is a plastic T used near the coolant reservoir on many late '90's and early 2000's Audis that fails often and a 3/8" brass PEX Tee replaces it perfectly for $1.25. I showed them to a local independent shop I work with and now then buy them in bulk. My guess is that you could find something that will work better than the factory part for less than $5 at Home Depot.

As for the alternator, you can get rebuilt units or grab one from Woodie for even less. They really don't fail often, so I wouldn't worry too much about using a used one. Get that stuff back together and see what else you find. Hopefully it will be OK...

[robdelorenzo]

Yes, the pulley sheared off (as seen in the photo) it's gone and nowhere to be found.
The belt was from Pelican and I'm pretty sure it was the right one.
The alternator still spins, the water pump spins, the rollers still have the required "resistance" (they don't spin for very long) The belt didn't even break!

I'm holding good thoughts that an alternator, a belt, a fixed hose and away I go!

[Nine8Six]

Originally Posted by robdelorenzo

I'm holding good thoughts that an alternator, a belt, a fixed hose and away I go!

Pick up below before everybody else does

Originally Posted by itsnotanova

I sell used alternators for $50 plus shipping.

[Qmulus]

Originally Posted by robdelorenzo

Yes, the pulley sheared off (as seen in the photo) it's gone and nowhere to be found.
The belt was from Pelican and I'm pretty sure it was the right one.
The alternator still spins, the water pump spins, the rollers still have the required "resistance" (they don't spin for very long) The belt didn't even break!

I'm holding good thoughts that an alternator, a belt, a fixed hose and away I go!

It is just semantics, but the alternator clutch/pulley did not shear off, it spun off. If it had sheared the shaft, you would have a snapped off alternator shaft. It looks to me like you could just install a new clutch/pulley assembly and it would be OK. The alternator has a one-way clutch on it so it will continue to spin and not throw the belt when you shift. This is kind of unique and not usually seen on other cars. What may have happened is that the clutch seized (they do fail occasionally) and when you shifted the momentum of the alternator unscrewed the pulley from the shaft and the pulley fell away. Normally the one-way clutch would slip in that situation, as it was designed to do. After that, the temperature and pressure in the cooling system got so high that the weakest point failed (that plastic fitting) and the cooling system blew. I don't understand why the cap wouldn't vent though...

That is my theory anyway. I bet if you look where this happened you will find the pulley pretty much intact on the street.

[robdelorenzo]

I've decided to have the idie take a look at things.
Yes, I could probably do the work and save the labor cost, but what's really important to me is his opinion once the engine runs again and gets up to temp.
I really hope I didn't kill my car.
I'll report back this afternoon.
You guys have been most helpful in gathering the info before deciding what to do.
So it's basically spend the $$, roll them bones, and see what's next....

[seningen]

Originally Posted by Qmulus

It is just semantics, but the alternator clutch/pulley did not shear off, it spun off. If it had sheared the shaft, you would have a snapped off alternator shaft. It looks to me like you could just install a new clutch/pulley assembly and it would be OK. The alternator has a one-way clutch on it so it will continue to spin and not throw the belt when you shift. This is kind of unique and not usually seen on other cars. What may have happened is that the clutch seized (they do fail occasionally) and when you shifted the momentum of the alternator unscrewed the pulley from the shaft and the pulley fell away. Normally the one-way clutch would slip in that situation, as it was designed to do. After that, the temperature and pressure in the cooling system got so high that the weakest point failed (that plastic fitting) and the cooling system blew. I don't understand why the cap wouldn't vent though...

That is my theory anyway. I bet if you look where this happened you will find the pulley pretty much intact on the street.

This was my point -- it did not look like it sheared to me...

My guess is you will be back on the road in no time --

Mike

[robdelorenzo]

I just dropped off the car.
We will see what he says in the next day or two.

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Thanks to all of you!