Wrong size pulley for tensioner on my 03 LS V8

[don-ohio]

Yeah,I had a few days off,and I thought I heard a little noise on my newly acquired 03 V8,so I checked the drive belt and it had some wear.
Tore into it yesterday and the water pump also has a little play, so I am now replacing the idler pulley,tensioner pulley(what this thread is about), water pump, Thermostat with housing, and drivebelt.
My plastic parts seem fine. The problem is that Auto-Zone sold me a pulley for the tensioner which is 1/2"or more larger than the old pulley. I have looked on parts places on the web and they show the correct size,3 inches in diameter.
I'm going in to Auto Zone in the AM to find the correct pulley or going to Ford and buy the whole tensioner.
PRETTY COLD working out there on the slab tonight. Got 4 gallons of Ford Premium Gold coolant today also,since I may be doing the same on my 04 LS V6 sometime. don-ohio ^)

 

[joegr]

I'd replace the whole tensioner. Usually it's not the pulley on the tensioner that wears out first. The other pulley they sold you me be the idler.

 

[All2kool]

I'd replace the whole tensioner. Usually it's not the pulley on the tensioner that wears out first. The other pulley they sold you me be the idler.

I agree here. Although I have not done this on my LS, I did replace the entire Tensioner Assembly on my LTC as it was noisy and 'jerky' when running.

 

[don-ohio]

Thanks,Joe and All2! I appreciate that.I'm gonna keep an eye on that tensioner,believe me. WHAT A CHORE getting that new belt on! I was out there working just now til it hit 12 deg F. I have to work early tomorrow so I couldn't wait for the last segment of the air bleed where you let it cool and top it up.
I got the proper pulley from AdvanceAuto and the tensioner works really like a new one.....smooth. Of course,not surprising that the AutoZone had the wrong pulley,too big,and so did AutoAdvance. But a more knowledgeable guy behind the counter told the guy waiting on me to check a few other numbers and he found it.Perfect fit.
Ford would've had to order my parts so I went the discount store route. If I see that tensioner jerking,I'll replace it for sure. Thanks! don-ohio ^)

 

[FDR]

Thanks,Joe and All2! WHAT A CHORE getting that new belt on!

Getting the belt on was much easier than taking the old one off on my 02 V8. Putting it on, I started with pushing it sideways past the tensioner pulley (the only one facing inward). I was able to get it through by pushing with two fingers on each side. Getting it off of the tensioner sucked. I was tempted to cut it off if it wasn't such a new belt. Other than that, the only difficulty I had was figuring out which pulley would be the one I stretch the belt onto last. I think the rounded upper idler was the easiest. No ribs, no flanges. Just wrench down on the tensioner to give you some slack

On my Taurus, it's easiest to just use a sock to pull the belt up onto whatever pulley is highest

 

[All2kool]

The Tensioner on my LTC has a 3/8 Socket indent for easy ON/OFF of the Serpentine Belt. Is this not the case for the LS?

 

[don-ohio]

UPDATE! Had to order the cap for the thermostat housing from Ford today...................FIFTY SEVEN BUCKS! Well, I wanted a spare.LOL! It comes in Tuesday.


Yeah,All2,getting the tension off was easy, but getting it to come out from behind the tensioner pulley was tough.I just cut mine and pulled it out. I figured if it was gonna give me much trouble going back in behind the tensioner I'd just loosen the tensioner a little.I think that's what Frank was talking about? don-ohio ^)

 

[Telco]

The Tensioner on my LTC has a 3/8 Socket indent for easy ON/OFF of the Serpentine Belt. Is this not the case for the LS?

You either fit a socket wrench extension in a square hole, or put a socket on the pulley nut. Changed my belt a while ago, can't remember which method this one required. I've seen both on the cars I've worked on.

 

[joegr]

The Tensioner on my LTC has a 3/8 Socket indent for easy ON/OFF of the Serpentine Belt. Is this not the case for the LS?

Yes, the same.

UPDATE! Had to order the cap for the thermostat housing from Ford today...................FIFTY SEVEN BUCKS! ...

Wait, how can that be. I thought your plastic parts would last forever with your depressurized system?
I just bought two of those caps a month ago from Tasca for $34 each.

 

[don-ohio]

Quote Joe: `Wait, how can that be. I thought your plastic parts would last forever with your depressurized system?
I just bought two of those caps a month ago from Tasca for $34 each. '

Not what you think,Joe. The only thing wrong with it was the O-ring,which I replaced. BUT I wanted to make sure to have a perfectly fine extra cap for future use. Nothing wrong with the integrity of the old plastic cap. don-ohio ^)

 

[FDR]

Yeah,All2,getting the tension off was easy, but getting it to come out from behind the tensioner pulley was tough.I just cut mine and pulled it out. I figured if it was gonna give me much trouble going back in behind the tensioner I'd just loosen the tensioner a little.I think that's what Frank was talking about? don-ohio ^)

Yes, that's what I was talking about. Once I turned the belt to slip behind it (for removal), I just pulled up on it pretty hard while rocking it back and forth. I think I ripped a rib or two off. There were already some more ribs missing from where the crank pulley tore into it when the belt fell off (an idler fell off). I also already had a replacement belt

 

[don-ohio]

Yeah,Frank,the space is not really adequate because the pulley is pretty wide. I've put on a LOT of belts,but that one was about the most difficult(maybe the cold weather made it harder).I had even kept it in a warm place until installation time. Next time I'll just loosen the tensioner a wee bit and give more space to work. don-ohio ^)