Belt Tensioner SNAPPED OFF

[TJC]

I've been noodling over this issue, is it possible that the fan clutch issue is related to this? There are now 3 clutches on the belt system (AC, Fan, Alternator). When they are functioning normally things are fine. If one locks up for even an instant, lots of extra stress. Constant applied stress is one thing, shock stress is quite another.

Any wear/roughness/stiffness in the idler bearing?

I had the idler pulley bearing go out on my 2005 Ranger, and it snapped the idler arm hard enough to get my attention. Ended up replacing the the idler arm assembly. But it did NOT break the casting when the bearing failed.

Or poor engineering design due to lighter more fuel efficient goals.

Or simply a bad casting.

Geez, one more thing to worry about.

Anyone know the build dates on these two trucks?

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[Dr. Zaius]

I tried doing a web search for this issue and these are the only 2 instances I saw of it.

Has it happened on other 2.3 EB engines?

 

[dtech]

I've been noodling over this issue, is it possible that the fan clutch issue is related to this? There are now 3 clutches on the belt system (AC, Fan, Alternator). When they are functioning normally things are fine. If one locks up for even an instant, lots of extra stress. Constant applied stress is one thing, shock stress is quite another.

Any wear/roughness/stiffness in the idler bearing?

I had the idler pulley bearing go out on my 2005 Ranger, and it snapped the idler arm hard enough to get my attention. Ended up replacing the the idler arm assembly. But it did NOT break the casting when the bearing failed.

Or poor engineering design due to lighter more fuel efficient goals.

Or simply a bad casting.

Geez, one more thing to worry about.

Anyone know the build dates on these two trucks?

Yeah that's the 1st thing I'd be checking on is the pulley bearings, often those serp belt configs have an idler pulley that is small and spins at a high rate, on Saabs the idler pulley was small and prone to failure, I think the recommended replacement was every 60k, I would remove the bearing plate , clean, regrease and reuse . It's also a good idea to occasionally observe the belts when the engine is running, I've seen weak belt tensioners that are whipsawing from slack in the belt and it's a matter of time before the weak point in the system let's go.

 

[notsolinear]

Not sure if this has already been said, but someone with professional experience should be able to analyze that metal fracture surface and tell you a lot about whether the failure was violent and sudden or if shows any history of weakness developing over time. That would help narrow down the theories about something locking up vs. repetitive stress from normal operation and design.

 

[TJC]

Years ago I spent 2 years taking an IBM sponsored robotics curriculum. It was based at NC State and Duke. A Duke professor headed up the material lab portion of the study agenda. It's been over 30 years now, but I do remember how he stressed that all metals are crystalline in atomic structure.
He emphasized how one dent on a steel wheel rim can and has caused the steel rims to fail catastrophically. Once the atomic matrix has a fault line, however small, the fracture can and does grow.

Even more interesting is the work of Nikola Tesla (probably the brighest mind of the last 200-300 years), and the tinkering of John Hutchinson with Tesla's experiments in frequency modulation effects on metals. Hutchinson had metals turn to jelly, distort, embed into non-metals, and levitate.
He is just as strange a duck as Tesla, but not a physicist at all. A search on Hutchinson effect will show demonstrations.

The only scientists he could find interested in his findings were associated with the US Military Industrial complex. I have a feeling they have matured the technology.

 

[LevittownFordParts.com]

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?

Hi Steve,
There have been 2 revisions of the front cover. All engines can use the latest number KB3Z-6019-C though.

2019 - KB3Z-6019-A
2020+ - KB3Z-6019-B

Both now supersede to KB3Z-6019-C

Please let me know if you have any other questions.
Thanks,
-Benny

 

[Dr. Zaius]

So $200 for the cover.

Looks like it would be a lot of work to swap out though.

Wonder if it requires removing the head or just removing the front accessories?

 

[TJC]

Hi Steve,
There have been 2 revisions of the front cover. All engines can use the latest number KB3Z-6019-C though.

2019 - KB3Z-6019-A
2020+ - KB3Z-6019-B

Both now supersede to KB3Z-6019-C

Please let me know if you have any other questions.
Thanks,
-Benny

The obvious next question is what has changed? Can you provide pictures of the 3 versions?

 

[Frenchy]

So $200 for the cover.

Looks like it would be a lot of work to swap out though.

Wonder if it requires removing the head or just removing the front accessories?

Most likely the accessories, valve cover and possibly the oil pan. Regardless not a fun one

 

[TJC]

OK, I've searched and found 3 images. -A, -B, -C. I'll post them below, but a cursory look shows no obvious differences. Maybe the catalogs have not been updated.

Version B

Version C

 

[Stevedbvik1]

Hi Steve,
There have been 2 revisions of the front cover. All engines can use the latest number KB3Z-6019-C though.

2019 - KB3Z-6019-A
2020+ - KB3Z-6019-B

Both now supersede to KB3Z-6019-C

Please let me know if you have any other questions.
Thanks,
-Benny

Thanks Benny. Is the cover exclusive to the Ranger or is it also used on the Broncos and Explorers with the 2.3L? If there’s any way to tell

 

[LevittownFordParts.com]

Thanks Benny. Is the cover exclusive to the Ranger or is it also used on the Broncos and Explorers with the 2.3L? If there’s any way to tell

Appears to be Exclusive to Ranger.

-Benny

 

[LevittownFordParts.com]

The obvious next question is what has changed? Can you provide pictures of the 3 versions?

Sorry we do not have engineering data to see what may have changed nor are there any product photos listed from Ford for any of these versions.

- Benny

 

[TJC]

Sorry we do not have engineering data to see what may have changed nor are there any product photos listed from Ford for any of these versions.

- Benny

Thanks Benny

 

[20_lariet]

Sorry we do not have engineering data to see what may have changed nor are there any product photos listed from Ford for any of these versions.

- Benny

Thank you Benny for gathering all that information!

I hope these are isolated incidents. I just wanted to share as these breaks are very similar and so others will look at the tensioner mounting area for cracks. It would be nice if FoMoCo would put out a technical service bulletin so a bigger audience can be aware of this potential issue before they end on the side of the road.

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