Originally Posted by Action4478

IIRC , the power steering pulley is pressed on too...I might not be on far enough...

Originally Posted by turbodremz

Ok so here's the report, and its still a dead end.

All the pulley's are 8 rib and clean, and smooth surfaces are clean, no nicks or cracks/dings. Checked everything with a straight edge and a laser guide, and its all spot on. Absolutely zero play anywhere except the power steering pump with is a confirmed 1/8'' which after talking to the dealership is normal.

Again, belt runs great at idle. Put the truck under load in park (just a stationary rev of the engine) and I can see the back-side of the belt start to ride up the back lip of the water pump, and the back of the crank pulley, and thats it. It stays straight everywhere else. Again, there is zero play in the water pump/fan, no leak, and iirc its less than 4 yrs old, and the crank pulley/harmonic balancer is in good condition.

Also at idle, I checked each pulley to see if by any chance it was shifting/had any play, and nothing. The slight play in the power steering pump wasnt even noticeable at idle when turning the wheel.

So my options are to:

Replace the tensioner AGAIN
Replace both idler pulley's
Replace power steering pump even though nothing is wrong with it
Replace pulley on the brand new vacuum pump
Replace the belt again


OR

Just sell it and move on. Frankly Im tired of trying to source the problem, and I know its been a short ordeal, but I dont have time to deal with this. The truck runs like a champ with 325k miles, but being down every other week due to a belt is getting old and costly.

So anyone have any suggestions for me at this point? Cause Im regretting selling my 5.9 Durango at this point.

Originally Posted by turbodremz

ok just got done looking at the alignment marks on the tensioner, and checking the mounting bracket for the accessories on the driver side (a/c, ps pump, vac pump) for any missing bolts, cracks, damage, etc...and again, nothing.

But I did notice one thing. I can see the old wear marks from where the belt normally sits on the smooth pulley for the vacuum pump, and the belt isnt sitting in the same place, the pulley is about 1/8'' farther back according to the wear marks.

Now the only issue I see with that NOT causing the issue, is that according to belt rotation, it would start to go off route on the power steering pump before the water pump...correct? Or should I pull the vacuum pump and move the pulley forward 1/8''? Or shim the vacuum pump to move it forward?

Originally Posted by turbodremz

Found the problem and I feel horribly ignorant simply cause I was looking at it the entire time. The vacuum pump pulley is installed back too far, not by much, but just enough to throw the belt off center as it rotates, causing it to go off center on the power steering pump, then the water pump.

So I gotta pull the vac pump, move the pulley about 1/8''-1/4'' forward and give it another shot. Hopefully it works, cause I have a potential buyer that is interested in it if I can solve the issue. I want to keep the truck, but with my up coming job I need something a bit more fuel friendly.