03 Excursion Belt Tensioner - Ford Powerstroke Diesel Forum
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Old 12-30-2007, 06:33 AM
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03 Excursion Belt Tensioner

Very annoying low frequency noise from front of 6.0L engine, especially at idle in drive. Dealer diagnoised belt tensioner as root cause. Wants to replace belt and tensioner, $600. Ouch. Out of warranty of course.
Considering doing it myself, I have not yet looked at the shop manual for repair procedure details for the belt tensioner repalcement. Can anyone who has done this repair advise as to difficulty or special/essential service tools that maybe required. Also, anthing else that I should replace while its apart. Thanks.
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Old 12-30-2007, 01:03 PM
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Free bump for ya!
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Old 12-31-2007, 08:23 AM
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6.0L Fan Clutch Wrench

Found shop manual procedure. Has anyone done the job without removing the radiator as called out in the procedure?

Also the manual calls out special tool 303-591 (Wrench, fan clutch nut) but OTC has a tool which they say is similar to 303-774. Want to make sure I get the proper size tool, is it a 40mm or 48mm size wrench?

Thanks.
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Old 01-05-2008, 04:52 PM
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Well the job is done. What a TERRIBLE design. It appears abolutely no consideration was given to serviceability.

Getting access to the the belt/tensioner took about two hours. Removing the fan shrould/clutch/stator was a chore. I am sure techs that service 6.0L's for a living may have had an easier time but I certainly had a rough go of it.

Had to cut the old belt as the tensioner would not budge so I could not release any tension on the old belt.

Installed the new tensioner, belt, two new idler pulleys, and the new design water pump pulley.

Tony
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Old 01-09-2008, 03:30 PM
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Its not too bad, just a pain in the knuckles.
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