Belt Tensioner SNAPPED OFF

[LevittownFordParts.com]

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.

I have not had the time to read through this entire post but incase you did how many occurrences were there?

I would not say that we are a huge dealer but based on our location probably a mid-sized dealership. With that said we have 0 sales in the past 12 months of any of those front cover part number versions.

- Benny

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[Frenchy]

I have not had the time to read through this entire post but incase you did how many occurrences were there?

I would not say that we are a huge dealer but based on our location probably a mid-sized dealership. With that said we have 0 sales in the past 12 months of any of those front cover part number versions.

- Benny

That we are currently aware of only 2 have snapped. From the other side of the computer it is hard to say what exactly happened for why it broke

 

[TheBadger]

Some light reading for anyone who's curious. Guy told me it was about $8K of parts and labor. Took a little over a month.

I have a 2020 also, what month was your truck made?

Build date is 08/20

 

[airline tech]

Some light reading for anyone who's curious. Guy told me it was about $8K of parts and labor. Took a little over a month.



Build date is 08/20

I am surprised they did not replace the Idler Puller so with that, then it boils down to the tensioner itself or weak mounting ear for it.

 

[TJC]

I've not looked yet... Is the idler pulley bearing a replaceable part? Maybe they replaced the bearing and are reusing the original pulley.

Looking at the pictures, both failures had identical fracture points.

I am going to state the obvious here... A bearing or tensioner failure should not destroy the mount point. The mount point should be designed and tested to withstand either of those failures. I actually hope that it was the tensioner or bearing that failed. These are items you can monitor when performing maintenance.

A casting weakness is more difficult to evaluate. There is little warning. No strange noises or rough bearings...

 

[Fitzmotor]

I hit this link from the electric fan topic, I know it's old!

I think the problem may be from contact with the block, actually that does not look like it's part of the block, so whatever that is, I wish the 2nd failure pic was clearer, or the contact mark could be from when it was wiggling around before it failed completely.

It looks like a long term witness mark though, and as everything expanded and cooled it stress cracked.

I wonder if the updated cover has a extra machining operation there for clearance, I wonder if I can squeeze a long feeler blade back there to check?

 

[Loweredon33s]

I hit this link from the electric fan topic, I know it's old!

I think the problem may be from contact with the block, actually that does not look like it's part of the block, so whatever that is, I wish the 2nd failure pic was clearer, or the contact mark could be from when it was wiggling around before it failed completely.

It looks like a long term witness mark though, and as everything expanded and cooled it stress cracked.

I wonder if the updated cover has a extra machining operation there for clearance, I wonder if I can squeeze a long feeler blade back there to check?

That is the foam cover for the injectors.
I have a fix for that problem.

 

[Fitzmotor]

Brilliant, it adds additional support, even if it did crack it would stay in place!

 

[Loweredon33s]

Brilliant, it adds additional support, even if it did crack it would stay in place!

That’s the plan, I’d like to try it on a broken one to see if it would repair one that is already broken.

 

[Dr. Zaius]

That’s the plan, I’d like to try it on a broken one to see if it would repair one that is already broken.

Where do you list it?

Is it available or still in testing or R&D?

Lots of folks might want it just for peace of mind. Like me. ?

 

[Loweredon33s]

Where do you list it?

Is it available or still in testing or R&D?

Lots of folks might want it just for peace of mind. Like me. ?

I’m still testing and determining costs etc. I think it’s wise to produce them though.

 

[9zero1790]

let us know when its ready

 

[Lonewolf831]

Had the same issue

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?

[/QUOTE

I had the same issue with mine at 50k they took about 3 months to fix due to covid and parts been hard to find,eventually I got her back and fixed with some other parts replaced bur they never found what caused the problem,now I'm at 67k and I'm having a bogging issue,I warm my truck up for 10 mins or so and go on my way once down the road at the stop sign when I give it gas it'll go and once it reaches 10mphs or so it'll bog down for a milli second and then it'll jump back to speed,they already replaced the tps did an ecu and transmission update and nothing has fixed the issue!! I barely got her back yesterday bur the issue is still there,now I'm gonna take it back and or do the lemon law probably cause I can't afford rental again I paid 3100 for 1 month and 3 days since it's on the extended warranty they don't cover rental

 

[Racket]

Had the same issue

Wait, a third? Call the LAWYERS!
?

Actually I'm intrigued to find out if this evolves into a real issue to watch for and how to anticipate it.

@Loweredon33s may be onto a preventative safety solution if so. It would never be endorsed by Ford but for those outside of warranty a consideration. Those of us with warranties would simply be faced with taking the mess to Ford for replacement.

 

[Lonewolf831]

Wait, a third? Call the LAWYERS!
?

Actually I'm intrigued to find out if this evolves into a real issue to watch for and how to anticipate it.

@Loweredon33s may be onto a preventative safety solution if so. It would never be endorsed by Ford but for those outside of warranty a consideration. Those of us with warranties would simply be faced with taking the mess to Ford for replacement.

I got the extended warranty on mine I'm at 67k now and got bogging issues when I accelerate from a dead stop it happens in the morning even if the truck has been warmed up for 10 mins after about 30 mins of freeway driving the issue goes away.i recently got it back Friday from the dealer supposedly they fix it but they didn't and they can't figure out what's causing it!they replace the tps sensor but I guess that wasn't the culprit

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