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Well, I finally got around to finishing up the photo's, which you can find here Dual Idler Pulley tensioner mod . Several things come to mind, that might help others in the install as well. First, you should have a set of TORX tools, as I only had a set of Hex wrenches, and they certainly aren't made for the job. Fortunately, Bigbopper had one of them off when we did my CPS, so I eventually did get it! I used a hack saw to cut off the pulley mount for the single unit off of the bracket, which is a forged aluminum and cuts well. You also have to cut or grind the gusset down about a 1/2" for the new dual idler tensioner to fit into the bracket. I used a grinder, and didn't do a pretty job, but one that did the trick! There are 15mm bolts, holding the bracket to the engine. I had a 15mm socket, which took off the top bolt, but two of the bolts are behind the pulleys, and you need a 15mm wrench to take them off. Of course I didn't have one, so I had to improvize, so I figured out that a 1/2" wrench fits these bolts just fine!  You have to remember to install the two bolts that will fit behind the pulleys prior to installing the new dual idler tensioner into the bracket. I personally found the hardest part of the install was trying to get the new serpentine belt on by myself. As Jimmie usually says...I felt like a real "goober" trying to hold back the tensioner, and trying to fit the new serp belt on.  When you first fit a crack bar, or ratchet into the slot of the dual tensioner to get some slack, there is a "pop" which allows the tensioner to move forward or back. It was quite the arm wrestling for me, of where I eventually (as you can see in one of the photo's) had sticks stuffed against my crack bar and one of the pulleys, to hold the dual tensioner back as far as possible, giving me the most slack that would be possible. I still had trouble, and eventually had to use a large screw driver to pry the belt onto one of the air conditioner smooth pulleys. The whole project took me about 2 1/2 hours, but those with the correct tools, and a helping hand for pulling back the dual tensioner, you could cut that time in half probably. Hopefully this is helpful to some, and if there is anything anyone can add to this install, please feel free to comment! Dale... |
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Dale, way to go! Thanks for posting all that. One little thing, if you could provide all the part numbers that you used so ALL the info is right here in one thread. That would be great. Also, is that the stock bracket off of your truck, that you modified? |
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Can you tell me the benefits that the dual has over the old system. I am always looking to better my truck but have never had any problens with my old belt system. I am getting ready to do the glow plugs and after seeing your post figured this would also be a good mod but didnt know if there was a defect with the old belt tensioner. Nice install. _____________________________________________________________ Take care, Jim |
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The stock, "single pulley" tensioner has a tendency to wear out the bearings in the tensioner quite quickly, and the dual pulley set up has a longer life. |
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Dale, That's a first rate job on the photos you put out!!! We appreciate you doing that!!! There's a TSB that I accessed from this web site awhile back, before I did my tensoiner upgrade. It had diagrams of what to cut away on your alt. bracket, and specifics. It also has P/Ns for the necessary parts, but I think the belt P/N has maybe been changed from what the TSB says. I wish I knew why we can no longer access that particular TSB. It's listed in the FAQs for our '94-'97s. I made a print out of it, and will try to get my wife to scan both pages, and put it in the photos here. Be patient though, our baseball season has started, and we no longer live at our home!  (Unless it rains!  )DZLJIM, yes, you're correct. You modify your own alt. bracket. There is a drawing at the Dieselmann's website (see my link in Dale's other thread from a few days ago) that is similar to what the TSB provides, and has P/Ns. But Dale's photos show this really well, and basically, all we're doing here is getting rid of the boss for the old single pulley tensioner, and part of the reinforcing rib, just to make clearance for the new dual wheel tensioner. HTH.
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Hey Dale, Nice job on the write up and pics!!! If you don't mind me ask'in, How much did this mod cost after all said and done???? Jeff |
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Part #'s guys...since I have the receipt in front of me. F8UZ-6B209-CA Dual Tensioner N10 List price $181.52 JK8-1227 V-Belt $67.64 F8UZ-8B656-AB Decal to replace old $30.36 These are the "Canadian" LIST prices, so they should be substantially less in U.S. dollars. Yes Jim, that is my stock bracket that I modified! In doing this mod, I give thanks to both Bigbopper (Roy) and BigFig (Jimmie) as Roy showed me his dual setup on his new '97 as well as he had a "dual tensioner" and explained what had to be done. Jimmie gave some excellent links (in my other post regarding this mod) of which I printed out HERE and followed. For anyone that missed the previous post, it can be viewed HERE for those interested. Jimmie gave some good tips in this post as well as Scottginfla. As I mentioned previously, perhaps having ALL the correct tools prior to doing the job will make things easier, and even better if you have a helper when installing the serpentine belt. Thanks Scott (Quadzilla) for explaining the reasons for this modification. My single idler pulley tensior (second one, as it was installed under warranty) was shot, and the pulley was actually rubbing on the pulley bolt, and Roy mentioned he could hear a grinding noise. I would hate to have run into this kind of problem "on the road" so the dual tensioner will give me peace of mind, knowing that the tension is spread over two pulleys rather than a single pulley. I believe this "dual tensioner" was an upgrade on the 99+ Powerstroke Diesel engines. One thing that I did, which I don't believe is essential, is that I put anti-seize on the bolts prior to installing them, as I plan on keeping this truck for a long long time, and if this ever has to be done in the future, it might make things a wee bit easier. Again, if there is anything I missed adding, let me know and I'll try to add more for those looking to do this mod in the future. Dale... |
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THAN'XS for the Info dale!!  Jeff |
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I have the TSB on the dual arm setup in my Truck Pictures, it is Article 98-23-14, there are two pages with part numbers and drawings. You can click on the link below and go to the bottom of my truck pictures. |
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Bigpiper...thanks for those two pages, as they basically explain it all. Dale... |
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Yeah, Bigpiper!! Da's what I'm talkin''bout!!!  Thanks for puttin' that out! I have a copy of that that I got from here, but I'm no longer able to access it for some reason.  Again, thanks!
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Your welcome, both of you, anytime I can help. Bill |
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Good job Dale, now I know who to call when I need to do mine Craig |
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One small thing I missed when I first posted the dual idler information, which I didn't even realize (which some of you may be in the same boat) which Roy (Bigbopper) pointed out to me this weekend, is that there IS an actual "gauge" to go by, which will tell you when your serp belt needs replacement. When looking at your idler (I would think you would find this on the single idler as well) on the back part of the idler (closes to the engine) which basically is under the alternator bracket, but still viewable....there are three lines (humps of aluminum is the best way to explain it) on this back part of the idler. On the front portion of the idler there is one long line..or hump, pointing to these three lines. Apparently your serp belt is in need of replacement when this line is showing "outside" of the three lines! I thought perhaps my serp belt was too tight, but when Roy told me of this clever way of checking it out, I found I was within tolerances of these three lines! I'm on the high side (meaning somewhat tight, because my belt is new) but has a long way to go (lots of "stretch" room) yet. For those that didn't know this, I thought this might be helpful! Happy Father's Day to those that are! Dale... |
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Good mod there PS 2000, I like to see mods that make our trucks even more dependable, see so many performance mods here, maybe too many? Good to get back to basics now and then. I have gone thru 3 factory single pulley tensioners and the last one I put on I went aftermarket, Gates I think. They did something different to them to make them hold up longer, seems like they extended them a bit. Takes the same belt. wasn't much cheaper than the Ford unit, maybe $20 less. If it goes again I will do the dual setup like yours. BTW, got lucky when the last one cratered, just so happens I heard it coming apart and shut everything down as qwik as possible. Cut the belts and drove the 5 miles home, babying it and watching the temps, shut it off a few times and coasted, piece of cake!! |
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Dual idler pulley tensioner mod...photo's.
Re: Dual idler pulley tensioner mod...photo's.
