Front belt tensioner bearing replacement - with pictures
After a few weeks of loud squealing (initially at 2000-2300rpm, but eventually at all revs), the bearing of the front serpentine belt tensioner finally failed recently. I wasn't able to get hold of a complete tensioner on the day I needed it, so I opted to change just the bearing. The following pictures may help anyone looking to do the same.
Here you can see the failed tensioner, sitting off centre due to the lack of ball bearings! I drove about 30 miles with it like this
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Removing the belt shows the problem a bit clearer. A 3/8 square socket drive (as shown) is used to rotate the tensioner, allowing the belt to be slipped off.
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Once the tensioner is off (by removing the long bolt on the lower part) the problem is quite obvious!
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Removing the remains of the bearing from the tensioner pulley. A hammer and screwdriver will get it out, although it will take a bit of time as it needs to come out bit by bit, rotating it after each tap.
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That did the trick
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The remains of the inner bearing are easily unbolted from the tensioner arm:
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Tensioner pulley, remains of old bearing, and brand new bearing. The bearing is a standard size - 40mm OD, 17mm ID, 12mm Thick, sealed on both sides. This one's from Brammer (BSL), SKF part number 6203-2RSH. 6203 relates to the sizes, 2RSH is the seal spec. I'm not sure what the H stands for, but a 6203-2RS is also fine. They are cheap on eBay - just google the part number. I needed mine asap hence Brammer, where it cost about 7 quid.
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New bearing ready for pressing in:
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Using a suitable socket (my 32mm socket had a 39.5mm OD which was perfect - make sure the pressure is on the outer part of the new bearing, not the inner) the bearing can be pressed in with the help of a vice and smear of grease. No need to heat anything up - it's not that tight.
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New bearing in place:
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Pulley bolted in place on the tensioner arm:
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Job done 8)
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The tensioner is then bolted back onto the front of the engine - ideally the fan should be removed to give you enough room to work. An extra pair of hands is also useful to slip the belt back onto the pulleys whilst the tensioner is held back with the 3/8 socket drive, as in the 2nd picture. I didn't take any photos of this stage because I was too busy swearing and trying to make a tool to remove the fan. 1 divorce and 3 upset neighbours later, job done Previously:
2005 D3 2.7 TDV6 S
1984 90 2.25 Petrol CSW
1992 90 200TDi Hard Top
1995 Discovery ES 300TDi
2003 90 TD5 Truck Cab
29th Jan 2010 3:32 am
Bushwanderer
Member Since: 27 Nov 2007
Location: Northern Rivers, NSW, Australia
Posts: 2050
Hi RM,
Great explanation!
Best Wishes,
PeterThe Bearded Dragon
29th Jan 2010 4:02 am
Matty 2332
Member Since: 02 Dec 2008
Location: West Yorkshire
Posts: 670
Thanks RM, very interesting
29th Jan 2010 6:46 am
bellautos
Member Since: 02 Feb 2006
Location: NorthYorkshire
Posts: 2532
Great write up! I had the same problem a few weeks ago, took mine out and was caked in mud Didnt bother trying to clean it or anything as my local dealer had one it stock (about £30 something). All better now and no squealing now at all! Filming something somewhere...
The ball bearings will be on the A30 somewhere between Redruth and Bodmin! Surprisingly, it made less noise without them, but I wouldn't recommend driving far with it like that. Ron, yours looks about the same as mine did - when was that? I think deep mud wading caused mine to eventually fail, but I've done 100,000 miles now so not bad going.Previously:
2005 D3 2.7 TDV6 S
1984 90 2.25 Petrol CSW
1992 90 200TDi Hard Top
1995 Discovery ES 300TDi
2003 90 TD5 Truck Cab
30th Jan 2010 2:49 am
ronp
Member Since: 29 Nov 2006
Location: North Yorkshire
Posts: 15275
ridgeback_moor wrote:
Ron, yours looks about the same as mine did - when was that?
Mine went around 115k last year.
When I first heard it I was pulled up outside an industrial unit in North Tyneside.
Thought the clatter was someone opening up a chain pull roller shutter.
All my bearings would've been strewn down the A19,
as I managed to drive it the 90miles back to North Yorks.
Looking at the condition of it, I was in total amazement that I actually made it...... always on the road less travelled 🚧
< ‘tis but a mere scratch …….. it’ll polish out.
30th Jan 2010 11:49 am
J@mes
Member Since: 10 Nov 2008
Location: Bomber County
Posts: 4547
Great guide, thanks! Mine has just started to squeal every so often, so I think I'll get it changed before it goes properly!2014 D4 XS
2005 D3 SE - Gone
30th Jan 2010 12:06 pm
J@mes
Member Since: 10 Nov 2008
Location: Bomber County
Posts: 4547
Got any dimensions for your fan removal tool?2014 D4 XS
2005 D3 SE - Gone
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Didnt bother trying to clean it or anything as my local dealer had one it stock (about £30 something). All better now and no squealing now at all! 
