Newbie (ok retard) needs help replacing drive belt - Dodge Cummins Diesel Forum
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Old 04-16-2010, 11:56 PM   #1 (permalink)
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Newbie (ok retard) needs help replacing drive belt

Alright Cummins guru's........
I need to replace the serpentine belt and looking for a starting point...

Was able to get slack in the tensioner to pull the old (cracked and delaminating) belt off one pulley, but still looking at where to start and finsh the install.

Does the tensioner need to come off? What is the belt removal/ installation procedure? Anyone have a diagram of the belt layout? I don't have a belt diagram under the hood.

Any help, tips, pointers would be appreciated.

The good news is, I finally found a use for my 13mm wrenches.... don't think i have ever used them on anything Japanese before!!

Murph
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Old 04-17-2010, 12:04 AM   #2 (permalink)
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The belt has to be slid on its side behind the tensioner, just make sure you have it facing the right way. Just pick a point thats easy to access while pulling on the tensioner to put on last.
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Old 04-17-2010, 12:09 AM   #3 (permalink)
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Tensioner doesn't need to come off, if you didn't note how the old one came off you should be able to google a routing diagram. The procedure goes as follows:

1. Remove tension, slip old belt off of alternator.
2. Tangle old belt in fan and various pulleys.
3. Cut old belt with pocket knife.
4. Hold new belt in position, slip bottom side around crank pulley
5. Tangle new belt in various pulleys
6. Double check diagram to make sure belt is tangled correctly, it is not
7. Remove
8. Repeat until belt matches diagram
9.Route belt around everything but alternator
10. Hold tension on tensioner
11. Slip off, bust knuckles, make up cuss words
12. Hold tension on tensioner again
13. Slip belt around alternator
14. Release tensioner
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Old 04-17-2010, 12:10 AM   #4 (permalink)
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luckily the pulleys are smooth or grooved so it lets me know which orientation the belt should have.

I was thinking the a/c compressor would be the last pulley to be installed, I can reach the tensioner from underneath the truck and take off the tension and slip the belt over the a/c pulley last.

Do I need to remove the fan, or fan shroud? Seems pretty tight quarters in there.

Would it be easier to remove the tensioner and re-install?
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Old 04-17-2010, 12:13 AM   #5 (permalink)
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lmeyer9916

Yeah it would be easier to get belt over alternator pulley (smaller wheel diameter)

Need to find the belt diagram.....
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Old 04-17-2010, 12:19 AM   #6 (permalink)
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If you've got a helper holding tension underneath the alternator is the easy start/stop point. If your goin solo then the a/c compressor is your best bet. just google 04 cummins 5.9 serpentine belt diagram, I tried it and there were 2 or 3 diagrams on various sites and even a few videos. might give youtube a shot also
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Old 04-17-2010, 12:23 AM   #7 (permalink)
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Found a diagram on google. Thanks for the advice.

Are you removing or loosening fan shroud?
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Old 04-17-2010, 02:00 AM   #8 (permalink)
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Originally Posted by murph2004 View Post
Found a diagram on google. Thanks for the advice.

Are you removing or loosening fan shroud?
NOPE do not have to remove or loosen fan shroud. But grab a buddy to help ya. No shame in asking someone to hold the belt why you are fishing it around pulleys. When you have it all in place get a good light and make for certain its in the grooved pulleys correctly. One groove off and the belt is junk in no time.
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Old 04-17-2010, 06:46 AM   #9 (permalink)
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i just did mine last week. A helper would have been nice..but nobody around. I found it easier to slip it over ac compressor last. Definately no fun to change if the engine is hot
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Old 03-21-2011, 11:15 PM   #10 (permalink)
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Quote:
Originally Posted by lmeyer9916 View Post
Tensioner doesn't need to come off, if you didn't note how the old one came off you should be able to google a routing diagram. The procedure goes as follows:

1. Remove tension, slip old belt off of alternator.
2. Tangle old belt in fan and various pulleys.
3. Cut old belt with pocket knife.
4. Hold new belt in position, slip bottom side around crank pulley
5. Tangle new belt in various pulleys
6. Double check diagram to make sure belt is tangled correctly, it is not
7. Remove
8. Repeat until belt matches diagram
9.Route belt around everything but alternator
10. Hold tension on tensioner
11. Slip off, bust knuckles, make up cuss words
12. Hold tension on tensioner again
13. Slip belt around alternator
14. Release tensioner
What he said
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Old 03-22-2011, 09:33 AM   #11 (permalink)
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I just changed mine on Sunday for the first time. Let me give you my take. Overall it's very easy. One, I have the service manual so that has a diagram which helped. I tried to access the tensioner from the top, but not enough room to get a breaker bar between the fan and the tensioner. I removed fan shroud...still no go. I then went underneath and was able to get the bar on the tensioner and get belt off. After struggling trying to get belt around the fan blades (which are VERY VERY sharp!) I just cut the belt.

To install new belt I started at the alternator and worked left to right, up to down. I then went underneath the truck and tried to get the belt around the tensioner ( this was a bit challenging, but it does fit!). Lastly I released tension on the tensioner and installed belt around AC compressor. Reistalled fan shround. Next time I may just flip back the rubber flange on the fan shroud rather than removing it. One thing to note...The wire coming from the fan down to the shroud has a metal surround. This was a little bent on mine such that when I rotated the fan by hand it would rub. I moved it around until there was no contact. You may wat to check this before you start her up after replacing the belt. Good luck!
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Last edited by BoonDoc; 03-22-2011 at 09:37 AM.
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Old 03-22-2011, 04:28 PM   #12 (permalink)
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murph

you're quite smart, not that other word, for gathering the information and changing the serp belt on a Cummins. not the easiest task for a DIYer new to Cummins 5.9 engines.

i've seen factory trained mechanics screw this one up.

you have now joined the exclusive Lovin' My Cummins Club, those who work on and fix their own rig. less than 10% of Dodge/Cummins owners ever look under the hood. makes the dealer shop owners rich

next, setting the valve lash

goodonya mate
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