1996 Subaru Timing Belt

I would take a look at the belt and the belt sprockets for wear. In my experience once a cogged belt "slips" once it should be replaced.

Is the belt slipping OR is the key in the pulley sheared and that is allowing the pulley to slip? Also look at the cogs and the belt. They may not match up.

The new timing set included a new belt and four cogged pulleys (including the tensioner pulley).

Or are you saying that the new belt was destroyed minutes after the initial installation?

I thought about the possibility of the crankshaft pulley slipping, both times I reset the timing, I used the mark on that same pulley and she fired right up. So I'm assuming that the belt is slipping on that one.

The belt cogs seem to fit nicely into all their associated spots.

I'm torn between buying a new tensioner and buying a new crankshaft pulley. (That one did not come with the timing set). Maybe I need both.

Put a mark on the pulley and the crankshaft. Run it till the timing goes out. Check to see that the marks still align.

Hi Tom

I think I know how you can tell if the belt is skipping. I would assemble everything with another new timing belt. Maybe the new one you bought is no good. Put the new belt on and mark one of the teeth with white out or paint. Make another mark on the corresponding tooth of the cam pulley. Run it. If problem is solved you know the belt was the issue. If it skips you will certainly know because the belt mark and pulley mark wont line up. You will know that the problem then lies in the tensioner or pulleys. Hopefully this will give you somemore info to solve the problem.