Archived Truck still down over serpentine belt

[Royk]

Had truck towed home after serpentine belt broke due to seized A/C pulley. Bought a non-A/C belt to bypass for now since I can't afford new A/C. I can't for the life of me get the belt on over last pulley, even with tensioner removed completely. Belt is a Carquest/Dayco Gold Label 5081103. It is 1.10" x 110.91 OC. I routed belt according to diagram on box. Then I came inside and checked here and saw a different routing. Tried the different routing and its worse. Read that a pin on tensioner needs to be placed in another hole to reposition tensioner when going from AC to non-AC. The only pin on my tensioner is on the back, positioning it on the bracket, but the bracket has only one hole, so it only goes on one way. I'm at my wits end!!!

 

[MichaelOverfield]

Not sure about the reposition for the non AC belt.. but that could be the issue.

How close is it?

I couldn't get the proper belt on mine the normal way. It was too stiff and it's a real pain given the limited space under the hood.

I was able to finally get it by removal of one alternator bolt, then rotating it slightly to get more slack. Once it was on I kept the tensioner retracted and used a lever to align the alternator back, install the bolt, then release the tensioner.

That said, it it's not even close, the reposition of that tensioner is needed first, or even my trick won't work.

 

[TMyers]

I've had a couple like that over the years. Try to have your last pulley in the loop be one of the smooth ones or runs on the back. This way you're not having to have the extra length to get the belt over the lip on the grooved pulleys. Also, make sure the belt is in the grooves good on all the pulleys. That little bit might be enough to hold you off. Get some help. It's hard to hold the weight of the tensioner while trying to work the belt on.

 

[sag2]

Or just get a little longer belt.

 

[Royk]

I forgot to mention I also removed the top bolt from the alternator but it still wasn't enough, but very close. Maybe if it were summer and warmer outside, the belt would have a bit of flex. Cold weather sucks! The belt routing on the box showed the smooth side of the belt on the outside of the tension pulley, the diagram I found here on TDR shows ribbed side of belt on inside of the tension pulley. Also gets close. I'm not sure which one is correct.

 

[TMyers]

I forgot to mention I also removed the top bolt from the alternator but it still wasn't enough, but very close. Maybe if it were summer and warmer outside, the belt would have a bit of flex. Cold weather sucks! The belt routing on the box showed the smooth side of the belt on the outside of the tension pulley, the diagram I found here on TDR shows ribbed side of belt on inside of the tension pulley. Also gets close. I'm not sure which one is correct.

Any smooth pulley will run on the back of the belt.

 

[NIsaacs]

This might help:

Nick

 

[Royk]

Nick, thanks. That is the way I originally tried it and its also the way shown on the box. However, look at https://www.turbodieselregister.com/threads/252170-Belt-Routing?p=2438707#post2438707 to see another way I tried it. He seemed to know what he was talking about. This is where I read about having to reposition tensioner.

 

[mwilson]

Royk,

I know it can be done but maybe it’s another threaded bolt hole, not a locating pin hole. Take a look for another bolt hole..
Read this post I just found on CF. I am mobile so am limited for resources. Later on I will be back home and can dig deeper..

http://www.cumminsforum.com/forum/3...or-06-dodge-2500-a.html#/topics/440680?page=1

 

[mwilson]

I know it’s been done successfully by others in the past. The hole may be full of crud....

The diagrams on CF match mine and show the tensioner swung upwards...

 

[Royk]

Yes there are other holes in the bracket that look like they'd work, but I saw none threaded. As you said, it may be full of crud. I finally got the belt on today with the diagram provided by Nick above and its too loose!!! Ugh! Not only that, but with the tensioner in its original position, it rubs against the fan. The truck did run that way and the PS worked, but the belt was flopping at the tensioner. Your link to that other post was very helpful, but reading the whole thing, raised more questions. I'd love to hear something definitive about moving to those other holes. I will investigate the other holes hopefully tomorrow if it isn't freezing and snowing.

 

[mwilson]

I've been looking hard, tensioner is the same part number with A/C or without A/C.....

See if another bolt hole lines up as you rotate the tensioner up keeping the locating pin in place......

Even checked the Mopar side of things...

Belt routing checks out on Mopar, same routing as I posted in the older thread.

View attachment Belt Routing.pdf

 

[mwilson]

Found the Cummins bracket that the tensioner bolts to....used whether equipped with A/C or not from what I can find....

States "Multiple Tensioner Loctions".......

 

[mwilson]

Just got off the phone with Cummins, they will not send me the engineering print for this part....I was even going to order one but none are available.

HOWEVER he was very nice and once I told him what I was up to he said there are indeed TWO locator pin holds and TWO threaded bolt holes to allow for TWO tensioner locations.

Clean it up, they are there.....

 

[mwilson]

I just remembered the thread where the gentleman had really nice pictures of his freshly redone engine...looked and one of his pictures shows the two different tensioner locations....

Here you go.....

 

[Royk]

Mwilson,

Thank you, thank you, thank you!!!! That is the photo I've been dreaming of!! Thank You!

Last night I was looking at getting a new A/C compressor just to put this mess behind me.

Had to work late tonight and had no time or energy to work on the truck. Hopefully tomorrow.

Thanks again.

 

[mwilson]

Do me a favor once you figure it out. My truck is in storage until spring so can’t look at it.
Tell me which set of holes the tensioner sets in for the A/C equipped set up.
I’ll update the belt routing diagrams and use that same photo with a note regarding which holes are used for A/C and then no A/C.

 

[sag2]

You know you can now get just the pulley and clutch so you don't have to buy a compressor. It should be under $100.