Trick to change 2001 3.8 L fan belt

[migs_auto]

Used this once a few years back and again yesterday.

On my 2001 Grand Caravan EX the tensioner pulley has a 1/2 " notch to seemingly allow a using a 1/2 " ratchet to relieve tension. However, there is simply not nearly enough room for a ratchet (might be enough for a breaker bar with a swivel head, but I don't have one).

What you need: one or two 1/2 " extensions.

1. Jack up passenger front with dodge supplied jack or floor jack (i used floor jack)
2. remove Passenger front tire and plastic pulley cover (part of inner wheel well, sort of)
3. This exposes a good portion of pulleys and fan belt.
4.Here is the TRICK part: Position the 1/2 " extensions vertically such that one end is on the pavement or brick and the other is right under a squarish tab that is part of the tensioner pulley.
5. The extension should be almost vertical with a slight tilt towards the back of the car ( 2 or 3 deg)
6. Slowly (and I mean slowly) lower the car. As the car lowers the extension will make contact with the tab on the tensioner. Stop lowering the car. Make sure the extension is in a non slip position.
7. Lower the car further, as you lower the car the now firmly jammed extension will force the tensioner to release tension.
8. Now R&R the belt. No holding a bar to release the tension while you are trying to get the belt snaked into place. If you need a little more slack just lower the car a bit more.
9. Once the belt is in place raise the car a bit to tighten up the belt. Check for proper belt alignment once or twice as you tighten.
10. Once everything is aligned just raise the car until the extension gets loose and falls. Start the engine to check everything is good.
11. re-install plastic cover and wheel. you are done.

this take a little time but it also means you can do this job solo in your driveway and without the special Chrysler tool.

[RIP]

...or grind down a 15mm socket so it will fit. Works great on 3rd gen vans but would probably work on 4th gens.