Belt Tensioner Pulley Replacement

Conditions requiring pulley replacement are excessive pulley wear or pulley bearing noise usually resulting from extended operation in abrasive off-road conditions.

Using a 16mm closed-end wrench, remove the drive belt (8620) according to the Drive Belt Tensioner, Automatic removal procedure in this section.

Removal

NOTE: 7.5L (not F-Super Duty Motorhome Chassis) bolts have a left-hand thread, requiring clockwise motion to loosen the bolts. 4.9L and 7.5L F-Super Duty Motorhome Chassis idler pulley bolts, which loosen counterclockwise, have a conventional right-hand thread.

1. NOTE: Excessive rearward force on the bolt during removal may overstress and crack the tensioner arm.

   NOTE: Pulleys being replaced for suspected bearing wear should be evaluated for rough bearings. Bearing noise that continues or rapidly returns after a replacement pulley is installed is usually belt chirp rather than worn bearings. Bearings should rotate smoothly with a slight resistance due to the permanent lubrication.

   Using the 16mm wrench, loosen the belt idler pulley retention bolt or nut.

2. Remove bolt or nut and dust shield and remove the drive belt tensioner (6B209) from the tensioner arm locating boss.

Installation

1. Replace the pulley and reverse the removal instructions observing the correct rotation of the retention bolt.

2. Tighten bolt or nut to specifications.