The belt started to jump off the pulleys and I checked the belt tensioner and it was froze up, so I replace the belt tensioner and it called for 2 different size belts, 1 for under 8500 GVW and the other for over 8500GVW 1 belt is way to big 102" and the other belt needs to stretch like an inch to get it on with the tensioner pulled back all the way (with no tension on it). I checked belt diagrahms to make sure I was not routing the belt wrong and all the diagrahms I find for this engine and yr truck are not right pullies in places where there are none on mine.

Anyone have these problems before or am I just missing something

The truck is a 93 f250xl 4x4 with a 5.8efi winsor gvw8600

 

The belt on my 1992 F350 w/5.8L engine fits very snug. Make sure the belt is fully seated on each pulley before trying to get the belt positioned under the tensioner pulley. You will be amazed what a slight misalignment of the belt on one single pulley will make the belt look too short.

 

Just to make sure the tensioner moves to the left and is spring loaded to move to the right (towards the center of the engine). My experience with most tensioners is that you can put the belt over them then pull the belt over another pulley and the tensioner will spring backwards and then once over the pulley it will tension on it. This one seems like it is sprung all the way forward and if you pull on the belt it is trying to pull the tensioner pulley even futher towards the sprung direction. Its like you have to have 3 hands one to pull the tensioner backwards and then 2 more to pry the belt over another pulley.

Thanks I will look and make sure each pulley is seated, hmm that means I will need a few more hands.

 

There are several different belt routing/tensioner/idler pulley configurations on these trucks. I have no idler pulley with a single tensioner just above the alternator. I put the belt on around all the pulleys except the tensioner. Then I use a big breaker bar to pull the tensioner arm all the way back then I slip the belt underneath the tensioner pulley.

 

My 94 is the same when installing a new belt, just a hair to tight can't quite get it. Next size up belt is too loose.

What I do is allow the belt to pass over the idler pulley near the alt, the idler that makes the belt dip down then back up to clear the top rad hose, hose passes over belt at that point.

After a couple days or so running it that way the new belt has had time to stretch just a hair and fully seats into the other pulleys, at the point it will fit like it should, I can put it so it passes down under that idler as it should be.

If you do it that way one thing check for/keep in mind, be sure it won't hit the bottom of the top rad hose (real close without passing under idler). I temporarily secure the upper rad hose, I tie it up to the breather tubes for those couple days while the belt runs over top of that idler for some added clearance.