Dodge Ram Truck 1500-2500-3500. Manual — part 231

BELT-DRIVE

DIAGNOSIS AND TESTING

ACCESSORY DRIVE BELT

VISUAL DIAGNOSIS

NOTE: 5.9L DIesel Engine - If a belt is broken or frayed, inspect engine speed sensor ( located near the
crankshaft damper) for damage.

When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from
rib to rib , are considered normal. These are not a reason to replace the belt. However, cracks running along a rib
(not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has
excessive wear, frayed cords or severe glazing.

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
noise condition, inspect all of the accessory drive pul-
leys for alignment, glazing, or excessive end play.

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ACCESSORY DRIVE

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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 objects from
pulley grooves. Replace belt.

2. Installation damage

2. Replace belt

RIB OR BELT WEAR

1. Pulley misaligned

1. Align pulley(s)

2. Abrasive environment

2. Clean pulley(s). Replace belt if
necessary

3. Rusted pulley(s)

3. Clean rust from pulley(s)

4. Sharp or jagged pulley groove
tips

4. Replace pulley. Inspect belt.

5. Belt rubber deteriorated

5. Replace belt

BELT SLIPS

1. Belt slipping because of
insufficient tension

1. Inspect/Replace tensioner if
necessary

2. Belt or pulley exposed to
substance that has reduced friction
(belt dressing, oil, ethylene glycol)

2. Replace belt and clean pulleys

3. Driven component bearing failure
(seizure)

3. Replace faulty component or
bearing

4. Belt glazed or hardened from
heat and excessive slippage

4. Replace belt.

LONGITUDAL BELT CRACKING

1. Belt has mistracked from pulley
groove

1. Replace belt

2. Pulley groove tip has worn away
rubber to tensile member

2. Replace belt

9

GROOVE JUMPING

9

(Belt does not maintain correct
position on pulley)

1. Incorrect belt tension

1. Inspect/Replace tensioner if
necessary

2. Pulley(s) not within design
tolerance

2. Replace pulley(s)

3. Foreign object(s) in grooves

3. Remove foreign objects from
grooves

4. Pulley misalignment

4. Align component

5. Belt cordline is broken

5. Replace belt

BELT BROKEN
(Note: Identify and correct problem
before new belt is installed)

1. Incorrect belt tension

1. Replace Inspect/Replace
tensioner if necessary

2. Tensile member damaged during
belt installation

2. Replace belt

3. Severe misalignment

3. Align pulley(s)

4. Bracket, pulley, or bearing failure

4. Replace defective component
and belt

DR/DH

ACCESSORY DRIVE

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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
vibration

5. 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 object

1. Correct rubbing condition

2. Excessive heat causing woven
fabric to age

2. Replace belt

3. Tension sheeting splice has
fractured

3. 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 matrix

4. Replace belt

REMOVAL

3.7L/4.7L ENGINE

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 main-
tained by an automatic (spring load) belt tensioner.

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..

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ACCESSORY DRIVE

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5.7L ENGINE

1. Remove the air intake tube between intake mani-

fold and air filter assembly..

2. Release the belt tension by rotating the tensioner

counterclockwise with a 15 mm wrench on the
tensioner pulley bolt. Rotate belt tensioner until belt
can be removed from pulleys.

3. Remove belt.

4. Gently release tensioner.

5.9L DIESEL

CAUTION: Do not attempt to check belt tension
with a belt tension gauge on vehicles equipped
with an automatic belt tensioner. Refer to Auto-
matic Belt Tensioner in this group.

NOTE: The belt routing schematics are published
from the latest information available at the time of
publication. If anything differs between these
schematics and the Belt Routing Label, use the
schematics on Belt Routing Label.This label is
located in the engine compartment.

Drive belts on diesel engines are equipped with a
spring loaded automatic belt tensioner.

This belt tensioner will be used on all belt configura-
tions, such as with or without air conditioning. For
more information, (Refer to 7 - COOLING/ACCES-
SORY DRIVE/BELT TENSIONERS - DESCRIPTION).

Belt Routing - 5.9L Diesel Engine Without A/C

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ACCESSORY DRIVE

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