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Old 08-28-2010, 04:16 PM   #1
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Serpentine belt won't fit

I knew I would need help sooner or later. 2002 Wrangler 2.5 with AC. Bought replacement serpentine belt tried to install it and it is too short. It is a Dayco belt, part no. 5060923. It's the only brand belt I can purchase locally. I checked the Dayco website and they claim this is the right belt. I checked the part number on the belt and the measurement and it measures 92.39 inches. My old belt, and I know it is stretched, measures 94 inches. Has any one had this problem with Dayco belts before? I tried putting it on different pulleys from start to finish and it is still way too short. No amount of prying will stretch it. The adjuster pulley is loosened all the way. Thanks.

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Old 08-28-2010, 04:22 PM   #2
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What adjuster pulley is loosened all the way? There is a spring-loaded belt-tension pulley near the top of the engine that is moved against its spring out of the way so the old belt can be removed and the new belt installed.

Look at the old belt to see if you can read its part number. The last digits are of course its length.

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Old 08-28-2010, 04:25 PM   #3
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Do you have it routed correctly? Check Stu's site for the correct routing diagram: Serpentine Belt Routing - 1
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Old 08-28-2010, 05:01 PM   #4
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Routing is correct. Belt part no. as stated is 5060923, the 923 represents 92.3 inches. The old belt measures 94 inches. I don't have a spring tensioner, the tensioner on mine is the pully below the power steering pump. You loosen the center bolt then you screw the adjuster bolt up and down to remove or tension the belt. This pulley is adjusted all the way down, not even touching the Dayco belt, yet the belt is so tight it will not go over all the pulleys.
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Old 08-28-2010, 05:03 PM   #5
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If the old belt is 94 inches, why are you trying to install a belt that is only 92.3" long? These belts don't stretch, they have fiber filaments molded length-wise into the belt to prevent stretch.
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Old 08-28-2010, 05:34 PM   #6
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Jerry, that's my question. The new belt, according to the manafacturer and the parts store website is the correct belt. I searched different manafacture belts for my vehicle and they are list the same length, 92.3. All online part stores that sell the Dayco belt list this part number as being correct. There is no way this belt is correct. I have changed many belts before and if faced with this problem I would get a belt that was longer, but was not listed for said vehicle. I was just trying to find out if members of this forum had to take that route rather than installing the belt that supposedly fits the vehicle.
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Old 08-28-2010, 06:14 PM   #7
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Regardless of what the Dayco site says, and you have changed it before and a 94 fits properly, get another 94.
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Old 08-28-2010, 06:22 PM   #8
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NAPA consistently tried to sell me the wrong length serpentine belt for my 4.0L engine and years later, their website still showed the wrong length. I used the p/n that was on my old belt to buy the right length and that was that. That some website says it is the right length means nothing.
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Old 08-28-2010, 06:36 PM   #9
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Thanks for the replies. The old belt is worn and you can't read any part numbers from it. I have only had this Jeep for several months and have not replaced the belt on it before. Once I find a belt to fit I will keep the sleeve for that belt if I need to replace it again.
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Old 08-28-2010, 07:20 PM   #10
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OEM Belt

Here is what is in the OEM Parts book.
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Old 08-28-2010, 07:23 PM   #11
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Bad picture, I hope this is better.
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Old 08-29-2010, 12:50 PM   #12
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True story.....I replaced my belt and found the old belt was the wrong one. Someone had put on (and I don't know how) a shorter belt and bypassed the tensioner pully. When I went to loosen the pully to get the belt off, I was perplexed and the pully didn't touch the belt. So I cut off the old one got a new and now it fits great. It also sounded a bit quieter after the new one was on. So I say make sure you get the right size for sure.
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Old 08-29-2010, 01:09 PM   #13
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Quote:
Originally Posted by mfdbrian73 View Post
Thanks for the replies. The old belt is worn and you can't read any part numbers from it. I have only had this Jeep for several months and have not replaced the belt on it before. Once I find a belt to fit I will keep the sleeve for that belt if I need to replace it again.
Just enter it in your owners manual

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