Belt too tight after head work
Thread Starter
|
New User
Joined: Sep 2004
Posts: 16
Likes: 0
Belt too tight after head work
1997 4.0 AWD. Last week we finished a head re-build and the only real problem was installing the serpentine belt. It was very tight. The belt was an after-market but was exactly the same size as the ford belt we took off. I confirmed with ford that the belt that was previously on was the correct one.
I paid a mechanic to help me and I wasn’t there for the entire time. He assured me that the belt that was on when we started was so tight that he removed the a/c pulley to get the belt off. The belt tensioner is almost fully loaded. At rest without a belt installed the tensioner arm sits at the 9:00 position but to get the belt on we had to force it to the 6:00 position which was as far as it would move. When we forced the belt on, the tensioner only moved back about a ½ inch at the most.
We also noticed that the tensioner arm had some play in it front to back which should not be there. The tensioner was replaced by ford at 66,000km and we now have 116,000km. We have also had the belt replaced almost every year under warrantee.
Is it possible that ford installed the tensioner incorrectly or used the wrong part. Is it possible that we installed one of the pulley's in the wrong location, but I don't think we did as the locations are cast into the heads. Or is it possible that this is normal for this vehicle? Any help/advise is appreciated.
I paid a mechanic to help me and I wasn’t there for the entire time. He assured me that the belt that was on when we started was so tight that he removed the a/c pulley to get the belt off. The belt tensioner is almost fully loaded. At rest without a belt installed the tensioner arm sits at the 9:00 position but to get the belt on we had to force it to the 6:00 position which was as far as it would move. When we forced the belt on, the tensioner only moved back about a ½ inch at the most.
We also noticed that the tensioner arm had some play in it front to back which should not be there. The tensioner was replaced by ford at 66,000km and we now have 116,000km. We have also had the belt replaced almost every year under warrantee.
Is it possible that ford installed the tensioner incorrectly or used the wrong part. Is it possible that we installed one of the pulley's in the wrong location, but I don't think we did as the locations are cast into the heads. Or is it possible that this is normal for this vehicle? Any help/advise is appreciated.
Senior User
Joined: Mar 2001
Posts: 403
Likes: 0
From: cincinnati hamilton
there are two different belt sizes on the 4.0 . i think its with or without the ac compressor. i have a 91 4.0. i replaced the alternator and belt about a year or so ago.i remembered it was a super tight fit. it wasn't till much later, then i realized , i had the wrong size on mine for almost a year, finally bent the alternator till it wobbled and screeched .auto zone had sold me the wrong one the year before. only found out by chance comparison of belts. new one went on much easier. all along they swore it was the right size.so never underestimate human error. it might be worth a double check
unless something is not tightened down all the way, i don't think you can mess up the pulley placement my 2 cents worth.
rick
unless something is not tightened down all the way, i don't think you can mess up the pulley placement my 2 cents worth.
rick
Postmaster
Joined: Apr 2001
Posts: 3,818
Likes: 3
I agree, wrong belt size. I've had the opposite occur with aftermarket belts - where it is slightly too long allowing the compressor pulley to squeal - so some caution is in order when using aftermarket, especially the less expensive ones.
Thread Starter
|
New User
Joined: Sep 2004
Posts: 16
Likes: 0
Today I did some more checking and from everything I could find out the belt that I have on is the correct size. The aftermarket belt is the same size as the ford belt that I had on before and ford confirmed that it is the correct belt.
I may have to take the vehicle back to ford to solve the mystery but this would be my last resort. I was going through the numerous ford work orders and remembered that they had changed the alternator a couple years ago. Could they have put on a larger pulley? Usually they take the pulley off the old alternator but if the pulley was damaged maybe it was changed.
I think that I will try to find locally a 97 4.0 with a/c to compare the components.
I may have to take the vehicle back to ford to solve the mystery but this would be my last resort. I was going through the numerous ford work orders and remembered that they had changed the alternator a couple years ago. Could they have put on a larger pulley? Usually they take the pulley off the old alternator but if the pulley was damaged maybe it was changed.
I think that I will try to find locally a 97 4.0 with a/c to compare the components.
Senior User
Joined: Mar 2001
Posts: 403
Likes: 0
From: cincinnati hamilton
now thats a puzzler....is there a difference in belt routing on awd vs rwd 4.0 engines? thats a good idea to compare.with other 4.0 engines.maybe some in used car lots, if you don't know of otherones..take a tape measure and measure across the middle of the alternator pulley. recheck belt diagram on hood of engine for routing.?? .. rick
Postmaster
Joined: Sep 2003
Posts: 4,452
Likes: 1
From: Southern California
No difference between RWD and 4WD as far as belts are concerned. Also, when you but the belt on for the 4.0L, if you do it correctly, you won't go over the fan. Everything can be done without ever having to put the belt over the fan.
Trending Topics
Elder User
Joined: Dec 2004
Posts: 718
Likes: 0
From: North Jersey, New Jersey
Not to sound stupid but are you sure you are routing the belt correctly I think the engine is designed so that it only fits one way but just checking anyways I don't have a 4.0 on my 3.0 the belt won't fit unless you have it right.
If your not sure you can get diagrams and all kinds of part specs from alldatadiy oddly enough they cover engines in more detail then my Haynes manual.
If your not sure you can get diagrams and all kinds of part specs from alldatadiy oddly enough they cover engines in more detail then my Haynes manual.
FTE Stories
Ford Trucks for Ford Truck Enthusiasts
10 Ugly Ford Trucks That We Still Kinda Love
Joe Kucinski
10 Things Every Truck Owner NEEDS (2026 Edition)
Michael S. Palmer
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Verdad Gallardo
Top 10 Most Expensive Ford Trucks Ever Sold on Bring a Trailer
Joe Kucinski
2027 Ford Super Duty Buyer's Guide (Every Model, Engine, & Package)
Brett Foote
Top 10 Ford Truck Tragedies
Joe Kucinski
AEV FXL Super Duty - the Super Duty Raptor Ford Doesn't Make
Brett Foote
Lobo Vs Lobo: Proof the F-150 Lobo Should Be Even Lower!
Michael S. Palmer
Ford's 2001 Explorer Sportsman Concept Looks For a New Home
Verdad Gallardo
here's the belt routing,
Thread Starter
|
New User
Joined: Sep 2004
Posts: 16
Likes: 0
[img]file:///C:/Documents%20and%20Settings/rob/My%20Documents/My%20Pictures/Belt.bmp[/img]
This is how the picture under my hood looks. There is so much pressure on the tensioner that it is pointing straight down with the belt very close to the main part of the tensioner housing. Have not been able to see another van of the same specs as mine but that is still the plan.
This is how the picture under my hood looks. There is so much pressure on the tensioner that it is pointing straight down with the belt very close to the main part of the tensioner housing. Have not been able to see another van of the same specs as mine but that is still the plan.
Thread Starter
|
New User
Joined: Sep 2004
Posts: 16
Likes: 0
Looks like my picture didn't make it. From the previous with a/c picture if # 8 was the tensioner housing the tensioner arm and pulley runs toward the #8 circle with the belt on the outside not the inside. The tensioner pulley is grooved to fit the inside of the belt.
Senior User
Joined: Mar 2004
Posts: 144
Likes: 0
From: Singhampton
Have you checked all teh pulleys, i.e. do all the ribbed pulleys line up with the ribbed side of the belt, make sure there are no pullys with the flat side in contact with the ribbed side of the belt, if you have you may find a couple of pulleys got put back on in the wrong place, unlikely as they probably don't fit, but worth checking.
OK just had a look (mines a 4.0 AWD) and the only groved pullys are Power steering, air con compressor, crank and alternator, all the rest are flat with the outside of the belt running on them.
OK just had a look (mines a 4.0 AWD) and the only groved pullys are Power steering, air con compressor, crank and alternator, all the rest are flat with the outside of the belt running on them.
Last edited by x.l.r.8; Jan 6, 2005 at 12:54 AM.
Thread Starter
|
New User
Joined: Sep 2004
Posts: 16
Likes: 0
All the flat sides are against flat sides and the ribbed side of the belt sits in grooved pulley's. The tensioner pulley on my van is grooved and I see no other way to put the belt on.
Does anyone have a Canadian 1997 4.0 AWD with a/c and is your tensioner pulley grooved like mine?
Does anyone have a Canadian 1997 4.0 AWD with a/c and is your tensioner pulley grooved like mine?