So the tensioner went out on my 95 f350 7.3. Oem tensioner lasted 309,000 miles. Bought a new one from napa didn't fit called and verified part and it was correct. It only had one alignment pin and was way too small of a tensioner. Returned. Bought one from autozone. Arm was way too long and tiny pulley. Alignment pins were in wrong spot wouldn't slide all the way into the hole, arm with pulley hit mount casing on engine. Returned part. Advance auto had the same issue auto zone had. Oriellys part fit perfectly but the idler pulley won't go back on cause it hits the tensioner. I've searched all over for this issue and can't believe nobody has had this problem. Just about ready to pony up and buy a ford tensioner at $174!!!

 

Are you taking the old one in the store with you to matchup?

 

Consider converting to the SuperDuty belt and tensioner. It is a huge improvement.

Here's my threads on the issue:
https://www.ford-trucks.com/forums/1...questions.html
https://www.ford-trucks.com/forums/1...oesnt-fit.html

Here's a related thread:
https://www.ford-trucks.com/forums/1...r-pulleys.html

 

Took the old one to the store all the other times besides the first. All the stores said the tensioner has been redesigned for better reliability. Well they don't fit so it can't be very reliable.

 

Don't want to do the sd mod yet. Need to get the truck out of the parking lot first and back home. Never imagined it would be this hard to change a simple part.

What aftermarket tensioner fits this truck. Part #?

 

I initially used a Gates 38119, if I recall correctly. It did seem to work, just the idler pulley next to it would not. Check out my first thread's last page if you are having issues with the idler pulley hitting the tensioner - you may have parts missing.

 

I have had a ton of these trucks and can't remember ever having the problem you are describing. Are you sure something is not original?

 

I have two belt tensioner pulley assemblies from my `92 7.3. Call me and we figure something out.
Robert 530 263 5545

 

Pulled the bracket out and cut the mount with a bandsaw. Installed 2002 excursion dual tensioner.