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Old 10-20-2017, 06:20 PM   #1
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W20 Serpentine belt conundrum...

Today was going to be the remove the serp, tensioner, Idler and any other pulley making the angry Sparrow noises. I read several threads on doing all this from the ground, but some went in from the top of the doghouse.

No dice on the doghouse entry...can't see any of the belt or routing from there. I figured it would be accessible from underneath....nope. The fan blade(s) are in the way and I cannot get a 1/2" ratchet onto the tensioner square drive at all. I thought about removing the fan, and laying it in the housing....nope, the bolts are on the pulley which requires belt removal first.

Bottom half of the fan shroud is blocked by the coolant lines that run right underneath it. Sooooo, what am I missing here? I gave up and installed the rear axle SumoSprings so the day was not a loss at all......{sigh}
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Old 10-20-2017, 06:43 PM   #2
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Did check u tube for a video on how to For your engine make and year if not please do it’s all accomplished from underneath.
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Old 10-20-2017, 10:02 PM   #3
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I believe I used a 3/8 long handle flex head ratchet on mine, when I changed the belt. I did most of the work from below but also under the dog house.
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Old 10-21-2017, 07:02 AM   #4
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I believe I used a 3/8 long handle flex head ratchet on mine, when I changed the belt. I did most of the work from below but also under the dog house.
Correct, a 3/8" ratchet is what you want. I was able to snake it up from underneath and around most of the pulleys by myself. Couldn't pull back on the tensioner and get it around remaining pulleys. My son helped from the top side.

I replaced idler, tensioner and belt. I know the idler pulley was going but I still have noise. Guess the fan clutch is next.
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Old 10-21-2017, 07:35 AM   #5
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The noise I had in my 05 Dolphin was the A/C clutch.
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Old 10-21-2017, 07:42 AM   #6
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I'll crawl under there again & I could have sworn a 3/8ths was too small.

70ChevelleSS did you remove the fan to get to the idler and tensioner? There sure is not much room and having the lower shroud and fan off would make things a quite bit easier.

irsses, I did watch some videos and if I do pull the fan I will need to rent Fan Clutch Wrench set # 27018 from Autozone.....it''s a flat 36 and 57mm wrench.
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Old 10-21-2017, 07:43 AM   #7
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Yeah Speed, I hope it's not because the a/c is working good at the moment.
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Old 10-21-2017, 10:48 AM   #8
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When I did mine, I accessed it from the top and the bottom. I used small clips to hold it on top while I worked from the bottom. A helper would have been handy.

3/8 is the right answer.
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Old 10-21-2017, 03:28 PM   #9
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I didn't remove the fan. Hook the belt over one fan blade. Then rotate the fan slipping the belt over each blade as it goes around. Eventually the belt will be on the other side of the blades.
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Old 10-22-2017, 06:38 PM   #10
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Thanks for straightening me out, y'all were right it was a 3/8ths ratchet which did fit. Once the belt is off the Tensioner is next, then the Idler pulley.

Note: Autozone and AdvanceAuto have no parts for the Workhorse at all. But Advance stocks some Chevy Kodiak parts, so see if they match up.

Turns out that OReilly has some and a store in Johnson City(1.5hrs away) had the belt, tensioner assembly and the Idler in stock. Searching a 2004 Kodiak 4500 chassis 8.1 found the Tensioner and pulley. The Gates 108" Belt was not listed for it, but they had one in stock. I'll post the part numbers tomorrow.

Started it up and it's quite as a mouse!

Muy Bueno!
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Old 10-22-2017, 07:33 PM   #11
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Guess I'm lucky, my local O'Reillys is only about 3 miles. Bought all my old P32 parts there too.
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Old 10-22-2017, 09:17 PM   #12
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I got my parts from the Napa store, do they have those Where You Are?
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Old 10-23-2017, 06:16 AM   #13
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Yes we do and 30 min away(everything is at least 30 min away...lol). But Yesterday, after installing the Safe-T-Steer I looked up and said....let me give that serp another shot. Had everything on the ground in about 20min with no grief.

"Hmmmm, it's Sunday and rain is inbound for tomorrow & the Napa is closed". It was however a great day for a 3 hour bike ride, so it all worked out

They were right about the rain, it's been coming down since the early AM & I am glad Sheila is all back together, plugged in and parked in her carport.
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Old 10-25-2017, 06:40 AM   #14
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...Started it up and it's quite as a mouse!

Muy Bueno!
Glad that solved your problem. Wish it had solved mine. As I mentioned pulley bearings were going but I still have a noise that must be the fan clutch.
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