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Old 01-21-2012, 11:24 AM
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Join Date: Jul 2003
Location: Northern Virginia
Posts: 1,078
belt tension arm collapse

Working my way through some winter repairs including glow plugs, fuel line orings, voltage regulator, power steering pump hoses, injector line clamps, pcv set up, resonance flap cleaning, and belt tension shock and spring.

Once I got it buttoned back up, the only thing that made a lot of noise was the belt tension arm. I could see my belt riding forward some on the tension pulley so I figured the spacer behind the arm was worn. I could see that the arm's alignment wasn't exactly right so I bought a new one from Phil. I got the new spacer and seal ring from the dealer.

The 17mm hex head pin is tight (100nm), but came out as expected.

The arm has a bushing in the front and the back. The front bushing was worn through and part of it was completely missing. The spacer that fits between the arm and the engine had a .025" groove worn in it from rubbing on the arm.

The pin is also shot. Its supposed to be .944, but the bushings wore two big grooves in the pin to a depth of .926!

Going to order the pin today or on Monday, depending on whether Phil can get it or not.

Attached Thumbnails
belt tension arm collapse-img_4900.jpg   belt tension arm collapse-img_4904.jpg   belt tension arm collapse-img_4901.jpg  
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2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900
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Old 01-21-2012, 11:26 AM
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Join Date: Jul 2003
Location: Northern Virginia
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another pic

another shot
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belt tension arm collapse-img_4899.jpg  
__________________
2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900
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  #3  
Old 01-21-2012, 11:34 AM
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Join Date: Jul 2003
Location: Northern Virginia
Posts: 1,078
more pics

Fortunately the spacer is thick and took the brunt of the wear from the tension arm. It could have messed up the engine case which would have really been bad. Basically, the bushings fell apart then, what was left of the bushings wore out the pin ($105 part), and the spacer.
Attached Thumbnails
belt tension arm collapse-img_4910.jpg  

__________________
2009 E320 Bluetec 117,000
1995 E300D 306,000 Sold
1996 Ford Taurus LX 130,000 Sold
1985 300TD Still 225,000 Sold
2016 Ford Fusion 24,900

Last edited by connerm; 01-26-2012 at 08:53 AM.
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