geonc
my other 4X4
A nice upgrade is to ditch the single idler and install a dual idler like on the stooper doopy's
On '94/'97 PSD's the tensioner has a tendency to grenade.
You COULD spend$$$$$$$$$$$$ at the stealership for just a std replacment single pulley jobby
OR Spend about US $60 for a DUAL pulley tensioner.
Car Quest p/n 89257CQ and GreenStripe belt #K081223
The fix is realitvly simple.......{I did mine in the parts store parking lot with a cordless sawzall.......talk about REDNECK }
You need a T-50 TORX bit...remove the LOWER right idler and pitch it away.---rh thread---
Using a medium fine sawzall blade, remove the pully mounting boss down FLUSH-even- with the rest of the alt mount brkt.
I was able to do this with the alt brkt mounted....your experience/comfort level will dictate weather you remove the alt and brkt....6 bolts.
The CarQuest tensioner I KNOW does not require any milling to clear the spring boss....unlike the FORK factory unit that also costs twice as much
You might as well do it in your own garage and use an electric sawzall.....
with a 14-18 TPI metal blade and spend a couple $ for a tube of paste lube- it comes in a cardboard sleeve and you just place the blade at the edge and cut into the tube.
Go slow, watch for blade deflection--shouldn't be too much an issue as the majoirity of metal cutting blades max out at 6" long- The blade will get a little grabby as the cut progresses and you really can't get a real soild point of purchase for the swazall....so you are essentialy cutting freehand....just let the saw work and don't force it...the result will be worth it in it's smoothness and that = less time with a grinder smoothing it out and more time to enjoy that cold drink of your choice
Then install the new dual idler tensioner.
The new belt is 122 .75 inches.
The one you get from FORK {that costs more than twice} requires you to also grind the web area for clerance
I've had this set up close to 3 years now and travel about 700 mi a week so the parts are quality
Hope this helps!
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