Belt Tensioner SNAPPED OFF

[DukeCanBuildit]

id be tempted to snag that cover...

No kidding - might be easy enough to make an adapter and they’d never know it was missing. ?

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[ranger 2020]

And people wonder why dealers are aprehensive about giving out loaners. I remember a dealership that had taken the ashtrays out so the cars didn't smell. Wouldn't you know it, we got one of them back with burns on the carpet along with cigarette butts on the floor. Only takes a few to spoil it for everybody.

 

[CB750F]

OMG! Everything is falling apart at this company.
Glad it's covered OP.

 

[20_lariet]

6am, Saturday morning, I pulled out onto the arterial and got up to speed. Then a violent clattering from the engine, "check brakes" and "low oil pressure" warnings, so I stopped immediately and shut her off. I found the serpentine belt shredded and wrapped around the fan, and various tubes and wires severed. Eventually noticed the belt tensioner has snapped clean off and must have been slung into the radiator tank, because that's leaking. At the dealership now awaiting diagnostics.

Ford Performance tune, aFe charge pipes, mishimoto intake, 3" turbo back. Think they'll tell me the mods caused this?

 

[20_lariet]

Just happen to me.

 

[Frenchy]

So far only two that I have heard of. Who knows the true cause. Also sucks since the whole timing cover has to be replaced

 

[airline tech]

I have a feeling that this is a true weak point due to weight savings,
There is constant stress being applied to that ear (spring Tension) pulling outward to keep the belt tight, now add any rocking back and forth and it gets weaker and weaker.

So, now we have added another (Stress for the DIY), when you go to do a simple it's time to replace my belts, (Is it going to break off when you apply tension on it to remove the belt?)
Unfortunately, this is not like the Spark Plugs, with those you have a visual (hey, wait a minute-look at this) this may be a problem.

With that tensioner, it is hidden, possibly a hairline crack (viewable) and this is not an easy fix.

So, I wonder did this provide any early warnings, any abnormal noises that were being ignored.
Rattle, Squealing, Roaring noise?

MIGHT need to make this a preventive maintenance relace item, if this is the true failed part. Pulley Bearing, causing excess drag on it.
or
Is it something else on the belt drive that caused it, and this is just the weakest point in the system.
Possibly the Idler Pulley

 

[airline tech]

It may just be a MFG defect in either the casting or install of it, noted they are both 2020 My's, OP had 45K, curious about (20-Lariets) milage.
No matter the cause, it is still a bracket design that is a weak point, for the amount of tension that is on it. (Any abnormal stress on that belt drive is going to produce extra stress on that ear)
Item 12 (Idler Pulley) - Item 2 (Tensioner) - Item 3 (Water Pump) - Item 4 (Alternator)

With a high focus of the Idler Pulley as the possible main cause, I am referencing the OP's pics of the damage and I see an indication of burned belt (rubber) on that idler pulley, this to me indicates that locked up, stressed the tensioner, which in turn stressed the weak design point of the bracket ear.
As the belt (Rotation) is CW, (as viewed in driver's seat looking forward)
If the Idler #12 locks up it will be creating a pull-down motion on the belt and the tensioner will be pulling up (spring tension)
So basically, a tug of war
If that pull down motion is great enough it would be like a hitting the tensioner with a hammer, and the downward pull is strong enough to break the ear especially when at an RPM higher than idle.

So, in Physics terms the Moment (Torque Action) design is not properly supported at the bracket.
It works flawlessly until you have thrown in a failure of a bearing.

And the fix would be to add an extra support bracket (Between the Block Mount & Tensioner Mount-Points) to absorb that tension. (A Doubler)
This would alleviate the weak point and you would just have the normal belt breakage / squeal.

 

[TomC]

Just happen to me.

Sane amount of damage as OP? Any mods...I too have a 2020 lariat. what was your mileage?

 

[Stevedbvik1]

Wondering if the front cover is unique to the Ranger. The tensioner also fits 2.3L’s in the Bronco and Explorer. Maybe @LevittownFordParts.com could find out? Also if there’s been any “upgrades” since 2020?

 

[20_lariet]

Sane amount of damage as OP? Any mods...I too have a 2020 lariat. what was your mileage?

I have no engine mods.

Sane amount of damage as OP? Any mods...I too have a 2020 lariat. what was your mileage?

No engine mods.
I was 30 miles in to my drive on the freeway when I heard something coming from the front, and before I could scroll through the cluster I got charge system fault, engine coolant over temperature, service engine. All of which put the truck into limp mode. The belt did not do any damage.
This part was not even on my radar to look at when inspecting under the hood. I hope we can spread the word who ever has the engine across all models to look at the tensioner now. After I looked closer there is evidence that the break happened earlier and the rest let loose that night. Right now Ford quoted the replacement and labor at $3500.

 

[TomC]

Right now Ford quoted the replacement and labor at $3500.

That sucks. Warranty?

 

[NotBudule]

And off I go to reinforce the weak spot !!!

 

[TJC]

I have a feeling that this is a true weak point due to weight savings,
There is constant stress being applied to that ear (spring Tension) pulling outward to keep the belt tight, now add any rocking back and forth and it gets weaker and weaker.

So, now we have added another (Stress for the DIY), when you go to do a simple it's time to replace my belts, (Is it going to break off when you apply tension on it to remove the belt?)
Unfortunately, this is not like the Spark Plugs, with those you have a visual (hey, wait a minute-look at this) this may be a problem.

With that tensioner, it is hidden, possibly a hairline crack (viewable) and this is not an easy fix.

So, I wonder did this provide any early warnings, any abnormal noises that were being ignored.
Rattle, Squealing, Roaring noise?

MIGHT need to make this a preventive maintenance relace item, if this is the true failed part. Pulley Bearing, causing excess drag on it.
or
Is it something else on the belt drive that caused it, and this is just the weakest point in the system.
Possibly the Idler Pulley

AC or Alternator clutch cycles adding to the stress??? There is a problem, part seems to be a weak link.

One instance is an aberration, two instances a worrying trend, three instances! Houston!, we got a problem!

 

[MountainGoat]

And off I go to reinforce the weak spot !!!

Oh great another case of us modifying our Rangers just to make them not break down in a coupe years.

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