[schwartzy18510]

I've been working on a major overhaul and tune-up of a family member's 2006 Ford Escape XLT, as detailed in my introductory post. The Escape in question is equipped with the 2.3L I-4, 4WD, the CD4E automatic transmission, and has about 185K miles on the odometer.

I recently suffered through performed an alternator replacement, and proactively replaced the serpentine belt idler and tensioner pulleys (Gates brand, Rock Auto) while I was in there. I also planned to replace the serpentine belt with a Gates brand belt (P/N K060895) , which the Rock Auto catalog indicated was compatible with an '06 Escape with the 2.3L engine and A/C.

However, I found upon installation that the belt was so loose that it fit around all pulleys and under the smooth idler pulley without my even needing to release any tension from the tensioner pulley. I therefore double and triple-checked the belt routing diagram in the Factory Service Manual. There is no listing for the 2.3L, only the 2.0L Zetec; however, the belt routing for the 2.0L and 2.3L appears identical. PDF page 23 of the FSM lists the below belt routing diagram:

The belt simply does not fit, and is far too loose. I therefore checked the O.D. of the new alternator, idler, and tensioner pulleys against the originals, and they match exactly. As further confirmation that the new belt itself is to blame for the poor fit, the old belt fits on the new idler and tensioner with the same tension it did on the old pair.

I therefore successively ordered the below belts from the Rock Auto catalog, all of which also were far too loose:

1. ACDELCO 6K895
2. Continental 4060895
3. Dayco 5060895DR
4. Bando 6PK2275 — OEM supplier to Motorcraft
5. Motorcraft JK6902B — OEM branded part

Of these, the Bando belt was the closest to fitting, as I actually had to move the tensioner about an inch for it to fit on the idler pulley. It is listed as having an effective length of 89.5", which is approximately .5" shorter than most of the others. I thought we'd finally found a winner, but upon start-up I get a belt squeal every time.

I then took the original belt along with the others to my local TSC and threw them on their belt measuring tool just for sake of comparison — all of the other belts were 2" longer in circumference than my original belt, which currently fits and runs just fine.

I'm at a loss here — I double checked my VIN, model year, and engine displacement as listed on the driver door jamb and all are correct. I thought perhaps someone had replaced the 2.3L Zetec engine with a 2.0L at some point in the cars previous life, and perhaps that belt size is different. However, I learned through some reading that the 2.0L Zetec had a timing belt, while the 2.3L had a timing chain. It just so happens that I had pulled the valve cover to replace a leaking gasket recently, and have photo proof that my engine has a timing chain, as seen below:

I examined all other pulleys and none of them appeared altered or aftermarket. The original serpentine belt (no readable markings or brand) fits the new idler and tensioner just like it did the previous set, but is a full 2" shorter than all of the belts Rock Auto carries for my application (with A/C) — even the OEM Motorcraft belt. How can this be? Has anyone else experienced this? I'm at the end of my rope on this one and am hoping someone can help me shed some light on this.

 

[SCOOTER]

I installed a Gates serpentine belt on my a 2008 2.3 with A/C Escape, the belt was a little tight upon installation but it fits perfectly. That was 4 years ago.
I looked at Gates website, Gates.com & mine has the Part# K060919A.

 

[bangster]

Most of those belts have a common numbering system, some are just arranged differently.
6 ribs, 89.5 inches (or 2275mm)

The one for not having AC is 85.5-86 inches long.

So...it really does have AC right? I am kidding, AC (with at least manual controls) was standard on all models, I just find it odd that rockauto shows belts for without it (which seem to be the correct size...)

No discernible part numbers on the old belt?

This is the similar routing and component chart from the 2008 FSM, other than it being a more compact more angular transition between components, it is the same routing, which you know since you cam put the old belt on and it is fine. Ribbed pulled goes to ribbed side of belt, smooth to smooth, etc.

 

[schwartzy18510]

I installed a Gates serpentine belt on my a 2008 2.3 with A/C Escape, the belt was a little tight upon installation but it fits perfectly. That was 4 years ago.
I looked at Gates website, Gates.com & mine has the Part# K060919A.

Thank you for sharing what fit your '08! I'm still stumped though, because the Gates K060919A is showing as being 91.9" long, which is even longer than the 89.5" belts which we've tried to date and which were all too long. The belt routing diagram appears the same on the 2008 as it is on our 2006, based on @bangster's post above.

 

[schwartzy18510]

Most of those belts have a common numbering system, some are just arranged differently.
6 ribs, 89.5 inches (or 2275mm)

The one for not having AC is 85.5-86 inches long.

So...it really does have AC right? I am kidding, AC (with at least manual controls) was standard on all models, I just find it odd that rockauto shows belts for without it (which seem to be the correct size...)

No discernible part numbers on the old belt?

This is the similar routing and component chart from the 2008 FSM, other than it being a more compact more angular transition between components, it is the same routing, which you know since you cam put the old belt on and it is fine. Ribbed pulled goes to ribbed side of belt, smooth to smooth, etc.
View attachment 1883

Thanks a ton for your response, which was helpful on multiple levels. For one, I had no idea that A/C was standard on all models and across all trims, so the belts for non-A/C applications in the Rock Auto catalog are indeed puzzling. The decoding of the part number reference in regard to rib count and belt length (895 or 2275) was also helpful.

Last but not least, I appreciate the 2008 2.3L belt routing diagram — it's actually the exact same routing that we have on our 2006 2.3L, as while the the routing diagram for the 2.0L ZETEC in the factory service manual is technically correct, our 2006 has the more angular relationship between pulleys shown in the 2008 diagram you posted above.

Since our original belt measured 2" shorter than all of the new belts — even an OEM Motorcraft one — which were listed as fitting our application, and since the belts listed as fitting non-A/C applications run 3.5" shorter than the A/C belts, I may just try one of the non-AC belts, assuming that our original belt had stretched somewhat from new.

I don't know where else to turn, given that even the OEM Ford belt listed as fitting our application is nowhere close.

 

[SCOOTER]

Maybe your 2006 Ford Escape is an import or the engine has been replaced.

 

[LX302]

Did you ever find a belt to fit? An old trick is to wrap a string around the pulleys in the same routing of the belt and then measure the length. You can then go to the auto parts store and pick up the correct length and type within a few millimeters.

 

[schwartzy18510]

Did you ever find a belt to fit? An old trick is to wrap a string around the pulleys in the same routing of the belt and then measure the length. You can then go to the auto parts store and pick up the correct length and type within a few millimeters.

I don't have a definitive answer yet. @bangster turned me on to a possible compatibility / listing error in the Rock Auto catalog based on the fact that the Escape came standard with A/C, so there technically should not be A/C vs. Non-A/C belts for the 2.3L Duratec engine.

The non-A/C belts in the Rock Auto catalog are 3.5" shorter than the belts listed as fitting A/C applications, and since our original (used) belt measured 2" shorter than the belts fitting A/C applications, a non-AC belt that is only 1.5" longer than our used one may just fit the bill, despite our Escape being equipped with A/C.

I subsequently ordered a Gates K060861A belt for non-AC applications from Rock Auto, but have not yet made the 3-hour round trip to my brother's place to attempt the install. I will certainly report back here with how it goes!