Good to see you got it solved. Just a hint for next time or for anyone else reading this.... I always do the AC pulley last. I get everything on, including around the tensioner, then working from under the truck, pull the tensioner open (so the belt slacks), pop the belt over the ac pulley then release the tensioner.

Also, if you are having problems with your belt hopping a rip on the AC (usually evident from one side of the belt flying off it you didn’t catch it soon enough), the tensioner is probably warn. If you did have once side of belt come off make sure you check each accessory to see which one hopped a grove. The culprit is either a worn bearing or miss alignment on the accessory with the hopped grove, or more often the one before it. The plastic pulley on the tensioner is supposed to be flat all the way across. Mine had a big depression in it that looked stock but was actually worn
(this is why I did not catch it first time around). After my second belt failure I replaced the tensioner (not cheap!) and belt again and all is well.

 

Great information. My AC siezed the other day. I live in Canada and don't want to scare all the moose off. Would you have a part number or a length of the belt that is needed to bypass the Ac? I have a 2003 5.9 Cummins.
Thanks

 

try doing one with a 2nd cp3. talk about a PAI. It does make it easier to get the belt routed (stock or modified) by removing the tensioner pulley first to get the belt around it and have a LONG 1/2" drive ratchet