2003 DODGE RAM Service Repair Manual

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Page 313 of 2895

DODGE RAM 2003 Service Repair Manual ACCESSORY DRIVE BELT DIAGNOSIS CHART
CONDITION POSSIBLE CAUSES CORRECTION
RIB CHUNKING (One or more ribs
has separated from belt body)1. Foreign objects imbedded in
pulley grooves.1. Remove foreign ob

Page 314 of 2895

DODGE RAM 2003 Service Repair Manual CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessar

CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
CAUTION: DO NOT LET TENSIONER ARM SNAP
BACK TO THE FREEARM POSITION, SEVER DAM-
AGE MAY OCCUR TO THE TENSIONER.
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic (spring load) belt ten-
sioner.
(1) Disconnect negative battery cable from battery.
(2) Rotate belt tensioner until it contacts it's stop.
Remove belt, then slowly rotate the tensioner into
the freearm position. (Fig. 8).
INSTALLATION
Belt tension is not adjustable. Belt adjustment is
maintained by an automatic ( spring load ) belt ten-
sioner.
(1) Check condition of all pulleys.CAUTION: When installing the serpentine accessory
drive belt, the belt MUST be routed correctly. If not,
the engine may overheat due to the water pump
rotating in the wrong direction (Fig. 8).
(2) Install new belt (Fig. 8). Route the belt around
all pulleys except the idler pulley. Rotate the ten-
sioner arm until it contacts it's stop position. Route
the belt around the idler and slowly let the tensioner
rotate into the belt. Make sure the belt is seated onto
all pulleys.
(3) With the drive belt installed, inspect the belt
wear indicator (Fig. 9). On 4.7L Engines only, the gap
between the tang and the housing stop (measure-
ment A) must not exceed 24 mm (.94 inches). If the
measurement exceeds this specification replace the
serpentine accessory drive belt.
DRACCESSORY DRIVE 7 - 27
DRIVE BELTS - 3.7L / 4.7L (Continued)

Page 315 of 2895

DODGE RAM 2003 Service Repair Manual DRIVE BELTS - 5.9L
DIAGNOSIS AND TESTING - ACCESSORY
DRIVE BELT
VISUAL DIAGNOSIS
When diagnosing serpentine accessory drive belts,
small cracks that run across the ribbed surface of the
belt from rib

Page 316 of 2895

Page 317 of 2895

CONDITION POSSIBLE CAUSES CORRECTION
NOISE
(Objectionable squeal, squeak, or
rumble is heard or felt while drive
belt is in operation)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Bearing noise 2. Locate and repair
3. Belt misalignment 3. Align belt/pulley(s)
4. Belt to pulley mismatch 4. Install correct belt
5. Driven component induced
vibration5. Locate defective driven
component and repair
TENSION SHEETING FABRIC
FAILURE
(Woven fabric on outside,
circumference of belt has cracked or
separated from body of belt)1. Tension sheeting contacting
stationary object1. Correct rubbing condition
2. Excessive heat causing woven
fabric to age2. Replace belt
3. Tension sheeting splice has
fractured3. Replace belt
CORD EDGE FAILURE
(Tensile member exposed at edges
of belt or separated from belt body)1. Incorrect belt tension 1. Inspect/Replace tensioner if
necessary
2. Belt contacting stationary object 2. Replace belt
3. Pulley(s) out of tolerance 3. Replace pulley
4. Insufficient adhesion between
tensile member and rubber matrix4. Replace belt
REMOVAL
NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these sche-
matics and the Belt Routing Label, use the sche-
matics on Belt Routing Label.This label is located in
the engine compartment.
CAUTION: Do not attempt to check belt tension with
a belt tension gauge on vehicles equipped with an
automatic belt tensioner. Refer to Automatic Belt
Tensioner in this group.
Drive belts on these engines are equipped with a
spring loaded automatic belt tensioner (Fig. 11). This
belt tensioner will be used on all belt configurations,
such as with or without power steering or air condi-
tioning. For more information, (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/BELT TENSIONERS -
DESCRIPTION).
(1) Attach a socket/wrench to pulley mounting bolt
of automatic tensioner (Fig. 11).
(2) Rotate tensioner assembly clockwise (as viewed
from front) until tension has been relieved from belt.
(3) Remove belt from idler pulley first.
(4) Remove belt from vehicle.
Fig. 11 Belt Tensioner - 5.9L Gas Engines
1 - IDLER PULLEY
2 - TENSIONER
3 - FAN BLADE
7 - 30 ACCESSORY DRIVEDR
DRIVE BELTS - 5.9L (Continued)

Page 318 of 2895

DODGE RAM 2003 Service Repair Manual INSTALLATION
CAUTION: When installing the accessory drive belt,
the belt must be routed correctly. If not, engine may
overheat due to water pump rotating in wrong
direction. Refer to (Fig. 12) (Fig. 1

Page 319 of 2895

DODGE RAM 2003 Service Repair Manual Refer to ACCESSORY DRIVE BELT DIAGNOSIS
CHART for further belt diagnosis.NOISE DIAGNOSIS
Noises generated by the accessory drive belt are
most noticeable at idle. Before replacing a belt to
resolve a

Page 320 of 2895

DODGE RAM 2003 Service Repair Manual CONDITION POSSIBLE CAUSES CORRECTION
LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley
groove1. Replace belt
2. Pulley groove tip has worn away
rubber to tensile member2. Replace belt
9GROOV

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