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Old 05-16-2012, 09:40 PM   #1
Inforcus
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Serpentine belt tensioner problem

Hi guys, I have a 2000 Ford Focus Zetec DOHC. All is fine with my car except for the serpentine belt tensioner. In one year I broke three tensioner. I need know if any body here have the same problem or my engine have some poblem or is the Pep Boys tensioner bad quality and I need buy a original Ford Part.
I change the original factory tensioner because broke the ball bering at 77,000k mile. I bought a Peb Boys replacement and it only lasted three months, the tension was broke in two pieces, I place another Pep Boys tensioner and about nine months broke in the same form. What is the problem??? I have fear to drive long distance and return in the top of flat bed. Somebody can help me


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Old 05-17-2012, 12:31 AM   #2
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sorry to hear about that. the tensioners are very common to go bad. i don't know if you bought the brand new, but i never heard of them snapping in two. the only thing i could think of is your belt is too tight, but that's controlled by the tensioner.. odd, very odd indeed.
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Old 11-05-2014, 08:44 AM   #3
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Originally Posted by stealthzx3 View Post
sorry to hear about that. the tensioners are very common to go bad. i don't know if you bought the brand new, but i never heard of them snapping in two. the only thing i could think of is your belt is too tight, but that's controlled by the tensioner.. odd, very odd indeed.
We just had a ford motorcraft tensioner snap in two last night. (I'd post an image, but I don't have any way to do that at present)...

Luckily, it's an easy fix.
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Old 05-17-2012, 02:10 AM   #4
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I just replaced the pulley, the tensioner was fine....

Do you still have the original that you could just replace the pulley on it?
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Old 05-17-2012, 08:23 AM   #5
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Something is out of line... misalignment puts too much strain on the belt, so if you find the belt IS too tight that's probably your issue.
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Old 05-17-2012, 08:11 PM   #6
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Ok guys, Thanks for your help.
This is the tensioner broken, the other part and belt are missing in the road.
The tree tensioner are broke in the same form and in the same place. I do not know why, but is very peculiar.It is what i desire to know why and correct the defect. Or to eliminate serpentine and to use a individual belt system if is possible.
Any idea or advise.
Thanks


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Old 07-22-2012, 12:40 PM   #7
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EXACT same problem

Same exact part replacement (Dayco 89318), same results...broke exactly where yours did. Did you ever find a resolution?

Last edited by treecarp; 07-23-2012 at 03:51 PM.
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Old 07-23-2012, 12:12 AM   #8
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I'm running rebuilt tensioner made from that exact design. They last forever. I'd be looking at belt length issues, if belt was changed at the start of all that breakage and was slightly too long or short (mainly long IIRC) the tensioner can hit the stop repeatedly to break after starting a crack first. That is one of the stiffer spring models I like to rebuild, but the stiffer spring would aggravate the potential problem I just described. The tensioner must not hit or even come close to any stops through its' entire range of movement while in use if the right length belt is picked.

If I had you close I'd buy that broken one for $5. Spare parts, mon..........
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Old 07-23-2012, 06:09 AM   #9
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Try getting a belt made by a different manufacturer, and also check your belt routing. IDK about the Zetec, but on one of my old vehicles the belt could be routed 2 different ways- one way left slack, and the other way didn't.
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Old 07-23-2012, 04:09 PM   #10
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I'm working on a 2002 SE wagon, 2.0L DOHC Zetec with A/C. Definitely routed correctly. Problem began with a shop putting on a serpentine belt that was WAY too short (Dayco 5070665 at 77.56"). How they muscled it on there is beyond me. Needless to say, it completely mangled the factory tensioner assembly. Replaced assembly with above mentioned Dayco, and a MasterPro K060837 belt that's 84.242". Since then, 2 Dayco assemblies have broken, just as pictured above. Have now ordered a Gates assembly. The belt and all the other pulleys are in great shape. So you think the belt may be too long? Anyone know the exact length needed and/or brand/part number? Thanks for any help...this is past frustrating.
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