3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

How to Replace Tensioner

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Old Jul 15, 2010 | 12:49 PM
  #1  
donald.emmack's Avatar
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How to Replace Tensioner

If I buy the whole assembly, can I install it without removing the radiator etc? Looks like there is just enough room, but though I would ask. Also, do 3 bolls hold the assembly? Size of head?
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Old Jul 15, 2010 | 10:10 PM
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one bolt holds the assembly...just put a 1/2 inch drive into the slot, move it so the belt comes off then unbolt it...it is a $%#@! to say the least to get it in and out but it ain't that **** hard
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Old Jul 15, 2010 | 11:28 PM
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From: SoCal
Not counting removing and relacing the belt it is easy.Removing the air filter
box gives you pretty good acess
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Old Jul 16, 2010 | 09:49 AM
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From: Mid-Missouri
Yes, removing the air filter box helps, just did all of that Monday night. Be prepared to bang your knuckles up a little bit and be patient with it. More than once I got a little frustrated trying to get the bolt hole lined up.
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Old Jul 16, 2010 | 12:30 PM
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From: Midlothian, TX
What kind of symptoms did yall have to make you replace the tensioner? Did it go out all together or just make noise? Also what mileage are yall at? I havn't replaced mine yet and would like to know what to look for.
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Old Jul 16, 2010 | 10:27 PM
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From: Mid-Missouri
I'm at 137,000 miles, threw one belt last friday and left me stranded, threw another the following monday, finally got a new tensioner and all seems fine for now. Checked all pulleys, alignment, only thing I noticed on the old tensioner was a little bit of wear to one side of the plastic pulley.
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Old Jul 16, 2010 | 10:39 PM
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05 CTD2500's Avatar
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From: Bremerton, WA
My pulley started squeeling for the first few minutes after startup at about 40k miles. Replaced just the pulley and bearing much cheaper than buying the whole assembly (dayco brand from autozone, same as what is installed from the factory). If lots of miles I would replace the whole assembly.
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