Chrysler Full-Size Trucks 1989-1996 Repair Guide

Belts

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INSPECTION



See Figures 1, 2, 3, 4, 5, 6, 7 and 8

Trucks equipped with an automatic belt tensioner DO need their belts inspected as normal. However, for those trucks so equipped, you may disregard recommendations for belt adjustment. Be sure to inspect/replace the belts at the proper intervals, or as needed.



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Fig. Fig. 1: Look at the label affixed to the radiator support to determine correct serpentine belt routing

Once a year or at 12,000 mile (19,000 km) intervals, the tension (and condition) of the alternator, power steering, air conditioning, and air pump drive belts (as equipped) should be checked. Inspect the belts for signs of glazing or cracking. A glazed belt will be perfectly smooth from slippage, while a good belt will have a slight texture of fabric visible. Cracks will usually start at the inner edge of the belt and run outward. It is always best to replace all drive belts at one time, as a preventive maintenance measure, during this service operation.



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Fig. Fig. 2: An example of a healthy drive belt



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Fig. Fig. 3: The deep cracks in this belt will cause it to flex, build up heat and eventually fail



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Fig. Fig. 4: Roughness in one or more of the pulleys can cause critical belt wear down to the reinforcing cords



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Fig. Fig. 5: Installing a belt that is too wide will result in premature belt wear and eventual failure



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Fig. Fig. 6: Serpentine drive belt wear patterns

Loose accessory drive belts can lead to poor engine cooling and diminish alternator, power steering pump, air conditioning compressor or air pump output. A belt that is too tight places a severe strain on the bearings of the components it is driving which will lead to early component failure.



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Fig. Fig. 7: Serpentine drive belt trouble diagnosis chart



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Fig. Fig. 8: V-belt trouble diagnosis chart

There are two different types of belts that may be found on your truck, V-belts (single ribbed) and serpentine type (multi-ribbed). Both of these types may drive one or more accessories.

The material used in late model drive belts is such that the belts do not show wear as readily. Replace belts at least every three years.

On vehicles with matched belts, replace both belts. New 1 / 2 in. (13mm), 3 / 8 in. (9.5mm) and 1 /5 32 in. (12mm) wide belts are to be adjusted to a tension of 112 lbs. (600 N), and 1 / 4 in. (6mm) wide belts are to be adjusted to 80 lbs. (311 N), as measured on a belt tension gauge. Any belt that has been operating for a minimum of 10 minutes is considered a used belt. In the first 10 minutes, the belt should stretch to its maximum extent. After 10 minutes, stop the engine and recheck the belt tension. Belt tension for a used belt should be maintained at 110 lbs. (490 N) for all except 1 / 4 in. (6mm) wide belts, and at 60 lbs. (267 N) for 1 / 4 in. (6mm) wide belts. If a belt tension gauge is not available, the following procedures may be used.

ADJUSTMENTS



See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

Trucks equipped with an automatic belt tensioner do NOT need to have their belts adjusted. Be sure, however, to inspect/replace the belts at the proper intervals.


CAUTION
If equipped, the electrically operated cooling fan may come on under certain circumstances, even though the ignition is OFF. Be sure to disconnect the negative battery cable before servicing your vehicle.



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Fig. Fig. 9: Accessory drive belts and adjustment locations-3.9L V6 engine



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Fig. Fig. 10: Accessory drive belts and adjustment locations-2.5L 4-cylinder engine



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Fig. Fig. 11: Belt tension test points and routing of accessory drive belts-2.5L engine without air conditioning



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Fig. Fig. 12: Belt tension test points and routing of accessory drive belts-2.5L engine with air conditioning



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Fig. Fig. 13: Belt tension test points and routing of accessory drive belts-3.9L engine without air conditioning or power steering



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Fig. Fig. 14: Belt tension test points and routing of accessory drive belts-3.9L engine without air conditioning



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Fig. Fig. 15: Serpentine belt routing-5.2L engine without air conditioning



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Fig. Fig. 16: For engines with automatic tensioners, turn the idler pulley clockwise to relieve belt tension-5.2L V8 engine shown, others similar



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Fig. Fig. 17: Serpentine belt routing-5.9L diesel engine without air conditioning



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Fig. Fig. 18: Serpentine belt routing-5.9L diesel engine with air conditioning

Alternator Belt

See Figures 19, 20 and 21

  1. Position a ruler perpendicular to the drive belt at its longest straight run. Test the tightness of the belt by pressing it firmly with your thumb. The deflection should be 1 / 4 - 5 / 16 in. (6-8mm).
  2.  
  3. If the deflection exceeds these limits, loosen the alternator mounting and adjusting arm bolts.
  4.  



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Fig. Fig. 19: Loosen the alternator mounting bolt



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Fig. Fig. 20: Loosen the alternator adjusting arm bolt

  1. Place a 1 in. open-end or adjustable wrench on the adjusting ridge cast on the body, and pull on the wrench until the proper tension is achieved.
  2.  



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Fig. Fig. 21: Turn the adjuster to achieve the proper tension

  1. Holding the alternator in place to maintain tension, tighten the adjusting arm bolt. Recheck the belt tension; readjust if necessary. When the belt is properly tensioned, tighten the alternator mounting bolt.
  2.  

Power Steering

4-CYLINDER ENGINES
  1. Hold a ruler perpendicular to the drive belt at its longest run, test the tightness of the belt by pressing it firmly with your thumb. The deflection should be 1 / 4 in. to 5 / 16 in. (6-8mm).
  2.  
  3. To adjust the belt tension, loosen the adjusting and mounting bolts on the front face of the steering pump cover plate (hub side).
  4.  
  5. Insert a 1 / 2 in. breaker bar into the adjusting bracket and apply pressure until the belt tension is correct.
  6.  
  7. Holding the pump in place, tighten the adjusting arm bolt and then recheck the belt tension. When the belt is properly tensioned tighten the mounting bolts.
  8.  

V6 AND V8 ENGINES
  1. Position a ruler perpendicular to the drive belt at its longest run. Test the tightness of the belt by pressing it firmly with your thumb. The deflection should be 1 / 4 - 5 / 16 in. (6-8mm).
  2.  
  3. To adjust the belt tension, loosen the three bolts in the three elongated adjusting slots at the power steering pump attaching bracket.
  4.  
  5. Turn the steering pump drive belt adjusting nut as required until the proper deflection is obtained. Turning the adjusting nut clockwise will increase tension and decrease deflection; counterclockwise will decrease tension and increase deflection.
  6.  
  7. Without disturbing the pump, tighten the three attaching bolts.
  8.  

Air Conditioning Compressor

  1. Position a ruler perpendicular to the drive belt at its longest run. Test the tightness of the belt by pressing it firmly with your thumb. The deflection should be 1 / 4 - 5 / 16 in. (6-8mm).
  2.  
  3. If the engine is equipped with an idler pulley, loosen the idler pulley adjusting bolt, insert a pry bar wrapped with a rag, between the pulley and the engine (or in the idler pulley adjusting slot), and adjust the tension accordingly. If the engine is not equipped with an idler pulley, the alternator must be moved to accomplish this adjustment, as outlined under Alternator Belt.
  4.  
  5. When the proper tension is reached, tighten the idler pulley adjusting bolt or the alternator adjusting and mounting bolts, as equipped.
  6.  

Air Pump

  1. Position a ruler perpendicular to the drive belt at its longest run. Test the tightness of the belt by pressing it firmly with your thumb. The deflection should be 1 / 4 - 5 / 16 in. (6-8mm).
  2.  
  3. To adjust the belt tension, loosen the adjusting arm bolt slightly. If necessary, also loosen the mounting belt slightly.
  4.  
  5. Using a large wooden dowel or a pry bar wrapped with a rag to protect the pump from damage, carefully pry against the pump rear cover to move the pump toward or away from the engine as necessary.
  6.  


WARNING
Do not pry against the pump housing itself, as damage to the housing may result.

  1. Holding the pump in place, tighten the adjusting arm bolt and recheck the tension. When the belt is properly tensioned, tighten the mounting bolt.
  2.  


WARNING
Check to make sure that the V-ribbed belt is located properly in all drive pulleys before applying tensioner pressure.

REMOVAL & INSTALLATION



See Figures 22 and 23

On most vehicles, to remove and install a new belt, you will need to loosen the mounting bracket bolts of the component. Using a suitable pry tool wrapped with a towel or rag, carefully pry the component forward slightly to give easy access to slide the belt off and on. You may need to do this an additional component(s) in order to make removal or installation easier. Some models have a few belts running different accessories; if you must replace a belt in the rear, you will first have to remove the belt(s) that are in your way. Look at your truck first to decide how many belts require removal to access the belt in need of replacement.



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Fig. Fig. 22: For non-serpentine V-belts, loosen the adjuster, then remove the belt(s)



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Fig. Fig. 23: Make sure the serpentine belt is correctly placed on the parallel-running teeth on all the pulleys

For those vehicles equipped with an automatic belt tensioner, the same logic in accessing the belt applies. To remove a belt on these vehicles, use a socket or wrench to rotate the tensioner pulley and loosen the belt. To install, place the belt over all pulleys but the tensioner pulley, then back off the tensioner in the same manner and slip the belt over the tensioner pulley. When you release the tensioner, it is spring loaded and will automatically apply the correct tension to the belt.

 
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