Pulley Tensioner, Problem??

[ACerf]

I noticed that in Geno's that their "Boonie Box" has a Pulley Tensioner in it. This got me to thinking, is there are problem with them? How long will one normally last? My 03' has 108K on her at this time, and I am wondering if I am looking at this pulley Tensioner going bye, bye on me any time soon. Oo.

 

[Radshooter]

Now you got me wondering too. Is it the actual pulley? I am thinking it is a tool to insert into the existing tensioner to releive tension for belt changes. Not sure though. Nothing shown in the picture.

Good catch. I have looked at the boonie boxes for several years off and on now and never noticed that!!!

 

[ACerf]

Now you got me wondering too. Is it the actual pulley? I am thinking it is a tool to insert into the existing tensioner to releive tension for belt changes. Not sure though. Nothing shown in the picture.



Good catch. I have looked at the boonie boxes for several years off and on now and never noticed that!!!

I looked at the pulley tensioner on my truck. It looks like the part that Geno's is selling goes inside the assembly. There is a bolt in the center, 9/16" (I think). I am thinking that this is a big bearing of sorts. I know that if It breaks it could be a fun job when it is pouring rain and dark outside... . :-laf

We are going on a long trip and I didn't want to get stuck somewhere along the way!

 

[PGAdams]

the boonie box from what I can tell is just the pulley, not the spring-loaded arm (tensioner), plus all of the hoses, belt, filter(s).

off subject for a moment, I went to Northern Tool and found a serpentine Belt tool with several attachments, $14. 95.

Good item (tool) to go in the boonie box as well.

In fact, I used it, tested it when I swapped serpentine belts earlier this week. I had been using my long-handle torque wrench.

 

[JCarlisle]

Dodge just replaced a shredded belt and a bad Idler on my 05 57k on the Odometer Mechanic caught it as he was working on the turbo

 

[WCPoe]

I noticed that in Geno's that their "Boonie Box" has a Pulley Tensioner in it. This got me to thinking, is there are problem with them? How long will one normally last? My 03' has 108K on her at this time, and I am wondering if I am looking at this pulley Tensioner going bye, bye on me any time soon. Oo.

The pulley is plastic and I now keep an extra tensioner pulley and serpentine belt in my truck. I recommend you get both and keep in your truck. I also have a copy of the belt routing in my console as well.

The reason: I lost my belt and tensioner pulley when my input shaft let go. Apparently when the shaft broke the instant the instant acceleration let the belt shift off the pulley. The result was a shredded belt and a tensioner pulley that was chewed up. Although a pulley and belt wouldn't have helped me in my situation it would be a good bit of insurance if you're in the boonies as the pulley might be hard to locate.

If you lose the belt it can damage the pulley as well. I think your can change the belt with 2 tools, a 13mm box/open end wrench and a tool to release the pressure on the spring tensioner, like a 1/2 inch ratchet or breaker bar if I recall correctly. The only issue is the clearance between the tensioner mechanism and the fan blades/shroud.

PS: I think a tensioner tool would be a good item in your tool kit as well.

Here's an earlier post with the routing for my 2004. 5 with A/C:

https://www.turbodieselregister.com...ruck-goes-boom-what-happened.html#post2025920

 

[llotton]

Hey PGAdams, wouldn't by chance have the full name of that Northern tool or the number would you. I can't find it. thanks larry

 

[ACerf]

I am not sure I understand how the tension is released from the pulley? Is it the bolt in the middle of the pulley?

I have a diagram of the how the belts are installed under the hood, near the radiator. I think most Dodge trucks have that... don't they?

 

[WCPoe]

I am not sure I understand how the tension is released from the pulley? Is it the bolt in the middle of the pulley?

I have a diagram of the how the belts are installed under the hood, near the radiator. I think most Dodge trucks have that... don't they?

The tensioner arm has a 1/2 inch socket indention in it where you can plug in the breaker bar and release the spring tension. The clearance is tight and you almost have to feel the indention to find it. All my breaker bars were almost to thick. I'm going to find a dedicated tool to keep inthe truck for this. I think Lisle Tools makes one but I know they are fairly expensive. I believe I'll dig around in my shop and find a piece of flat bar stock and weld one up.



I ended up reaching down from the top of the engine and removed the whole assembly, (pulley and tensioner) and then changed out the pulley. For the life of me I can't remember why I did it this way unless it was the clearance issue. I think the 2004. 5 and up trucks have the fan shroud mounted to the engine which may cause the clearance problem like mine. It may be easier on the earlier trucks but that's only a guess.

 

[ACerf]

WCPoe... . Did you change it because it had a problem? And if it did what was it that told you something was wrong?

Upon farther inspection of the tensioner assy. I can see pretty much how the thing works. I have seen many tensioner bars online from $50. 00 down to $4. 25. . I bet that wouldn't last one job!

 

[WCPoe]

Mine belt shredded when my input shaft let go, pedal to floor and when it shifted to third the shaft let go. I assume the engine just instantly overspeeded and made the belt jump.



The belt looked like a mass of spaghetti and the pulley had about half of it chewed away. All looked perfect just a day or so before when I did my oil change.

The instant the shaft broke I heard a loud boom and smelled burning rubber soon thereafter. Since the pulley is plastic it may have broken at the edge or something and then the belt just started sawing through it as it tried to pull loose.