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Fan inside water pump wore a hole in the outside casing of the water pump. Replaced water pump and same thing happend less than 500 miles later. Does anyone know what would cause this? The water pump pulley is pushed out a quarter of an inch.
I've never heard of a water pump impeller wearing a hole in the outer casing. It sounds more like something outside the water pump must be rubbing through the case, but you surely must hear some horrendous noise while it's doing it.
What year and engine do you have?
Where specifically on the water pump casing is it wearing through? Did you do anything to the engine, any modification or other work involving the water pump or the water pump pulley prior to this first happening? Could the pulley be on backwards thereby pulling the shaft off center and causing the impeller to rub against the inner housing? Just some idle thoughts.