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How to Replace Idler Pulley 94-02 Dodge Ram 1500

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How to Replace Idler Pulley 94-02 Dodge Ram 1500

Created on: 2019-09-14

Check out this video to learn how to replace the serpentine belt idler pulley on your 94-02 Dodge Ram.

  1. step 1 :Removing the Idler Pulley
    • Familiarize yourself with the route of the serpentine belt
    • Insert a 14mm socket and serpentine belt removal tool into the tensioner
    • Turn the tensioner clockwise to loosen the belt
    • Pull the belt off the idler pulley
    • Release the tensioner
    • Pull the belt off by hand
    • Remove the 14 mm idler pulley bolt to remove the idler pulley
    • Remove the bushing washer
  2. step 2 :Installing the Idler Pulley
    • Install the bushing washer into the idler pulley
    • Install the idler pulley with the 14 mm bolt
    • Don't over tighten the 14 mm bolt
    • If installing an old belt, inspect the channels for dry rot and cracks
    • Fold the belt in half
    • Loop the belt around the crank pulley
    • Bring it over the water pump
    • Pull the belt over the alternator
    • Bring it around the A/C Pulley
    • Bring it around the belt tensioner
    • Pull the tensioner clockwise with 14mm socket and serpentine belt removal tool
    • Bring it around the idler pulley
    • Release the tensioner
    • Check the belt fitment on all of the pulleys
    • Run the engine for about 30 seconds and check fitment again

Tools needed for replacement

  • Ratchets & Related

    Ratchet

  • Sockets - Metric

    14mm Socket

  • Specialty Tools

    Serpentine Belt Removal Tool

Installation Video
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Hey, friends. It's Len here, at 1A Auto. Today, we're going to be working on our 1996 Dodge Ram 1500. This is the 5.9. I'm going to show you something very simple, removing and reinstalling an idler pulley. It's going to be very easy. I can do it, and you can do it, too. As always, if you need any parts, you can always check us out at 1AAuto.com.com. Thanks.

So next, we're going to take the serpentine belt off. To do that, you'd want to take note of the direction of the serpentine belt. Okay, where it goes over all the pulleys and all that, of course. Now, we're going to use our serpentine belt tool, which is available at 1AAuto.com. Give this a little squeeze. We're going to grab the belt over here behind the alternator, and just pull it off of the idler pulley, just like that. Okay. Bring this down. Get our tool out of here. Now, we have a clear view of what we need to do. Okay. So, we've got our idler right here. We're going to remove the mounting bolt. That's a 14 millimeter. Just get this on here. We're going to turn it to the left, counter-clockwise. Almost there. There it is. Get this off of here. Get that off of there. There's our idler pulley.

So, we have our idler pulley, whether it's new or it's used. Got this little bushing right here. That just goes right in there. And what that does, see how thick that is? See how big your hole is? If you don't put that in, and you just put your bolt in, all right, that's no good. This goes in, takes up the space. The bolt's going to go there. And then, this part goes right up against the engine, or up against the bracket. And then we're going to install it.

So, let's go ahead and give it a shot. Get our bolt and our pulley down there. I'll pull it away, just so you can see what I'm doing. I'm just going to screw it in right there. Try to. There we go. Okay. Turn this all the way to the right until it's bottomed out. Okay. It's bottomed out. I'm going to use one finger on my ratchet here. Let's give it a nice little tug, and that's it.

Get this off of there. Now, we'll just re-install the belt. Easy peasy. All right. So, it's time to get the belt back on here. Looks like it's pretty much on the majority of the pulleys already, because we didn't take it completely off. So, that's nice. Just going to bring it around. Put it up on here, up on there. Cool. All right. So, you're going to have your tensioner tool already. Just get this up on here. I'm going to take the belt. I'm going to bring it down underneath the idler. Get this back up onto the AC pulley. Cool.

All right. We'll relieve tension just by turning the tensioner clockwise. There we go. I like to go like this a couple times. Make sure you get all of your tool off of there. A lot of times the adapters like to stick on the tensioner, and you won't realize it until you're driving down the road, and you hear "ptong!" So now, you just double-check all of your pulleys. And you make sure the belt's on all the way around. Once you're sure that it's on just like this, you're going to start up the vehicle, let it run for a couple seconds, and then turn it back off, and double-check all of your pulleys to make sure the belt's sitting perfectly.

Thanks for watching. Visit 1AAuto.com, your place for DIY auto repairs, for great parts, great service, and more content.

Tools needed for replacement:

    Ratchets & Related

  • Ratchet

  • Sockets - Metric

  • 14mm Socket

  • Specialty Tools

  • Serpentine Belt Removal Tool


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