Belt Tensioner

[tugboatphil]

I was changing the belt today and using my usual method of putting a flathead screwdriver in the gap where the spring hooks to the case. I cracked the case.



Took the one off my 90 and did the same with it. I'm surprised it hadn't cracked long ago as much as I pryed it.



I think I can probably still use the newer of the two, as I priced $150 from the dealer and $106 from the Cummins Shop.



I have never been able to use the square hole for a breaker bar, as the tightening bolt gets in the way with it straight up and the intercooler pipe when it's horizontal. What method works without damaging this thing.



Oh yeah, I'm also not allowed in China Shops.

 

[Case500D]

Phil,



I use a long ratchet. The I can rotate the handle where I need to so I can operate the tensioner. Never tried to pry the spring. It doesn't take too long to change the front cover. It is easier to remove the radiator when doing the job.



Jeremy

 

[1stgen4evr]

the right tool

NAPA has a tool for the job. It comes with several inserts and can be set to different positions for best clearance. The long handle ratchet works well also.



I hope you mean that you broke the assembly case and not the timing cover. Save the old ones for the pulleys if those are good. I have replaced a couple. I don't know if all the first gens have the same assembly.



I don't think I would chance going out of the yard with a cracked case.



1stgen4evr

James

 

[tugboatphil]

Yes, it was the spring cover case of the tensioner. I've seen those tools at NAPA and other stores before, but never thought about getting one before. My 3/8" ratchets are the short ones, so I couldn't get any torque on it.



Thanks for the help!

 

[JLEONARD]

My 3/8" ratchets are the short ones, so I couldn't get any torque on it.

Me too Phil, and I use a pipe over the handle for leverage.

Jay

 

[GGott]

3/8 ratchet with a cheater on the handle..... Sorry about your tensioner... ...

 

[dan brooks]

Ditto the cheater pipe - I have an old bottle jack handle that fits perfectly over the end of my Craftsman ratchet, and it has become a permanent part of my tool kit.



IIRC, the Dayco part number for the tensioner is 89219. I paid around $70 for it at a local, independent parts house.

 

[tugboatphil]

Thanks for that Dan. I never even thought about a parts store having them. Not sure what luck I'd have at the salvage yard, but is there any difference from 89 on as to part difference? Do they still use this setup on the 04's?

 

[Greenleaf]

The 04 models are different as are the 94 and so too with the ISB engine. So I have found on my buses.



Good thing you don't work at the glass factory down by Cincinnati



-S

 

[dan brooks]

Phil - I'm not sure which years interchange, but here are a couple links that are good for finding part numbers to compare:



Express Auto Parts



Parts America



Auto Zone



You can play around with different years and see if the part numbers match up.

 

[tugboatphil]

Thanks, Dan!!

Local Dodge dealer $149. 00

Cummins shop in Roanoke $106. 00

NAPA $129. 00

Autozone $85. 99

Advance Auto Parts $85. 99



Advance will have it here by 4pm today. It showed a picture and it's the exact same part. Why the big difference??



Anyway, once again, a single post on this site has paid for my annual subscription. Thanks to all that responded!!