Can Tensioner Bodies Be Faulty in Some Way?
 

O.k.; I'm getting way to good at rebuilding the old mechanical tensioners. Or then again, maybe not...

I have rebuilt my tensioners with the O-ring, check valve, etc. kit three times in the last year. One of them keeps failing while the other seems to be o.k. It's the same one that fails every time. I always buy two kits and do both, so I know I'm getting one of them right. I have even switched the "bad" one from the right chain housing to the left, and back again. It fails no matter which side it is on. Is it possible that the casting itself is bad in some way? Bore out of round or not quite square, c-clip groove missaligned, or something like that? I'm getting about 4,000-5,000 miles between failures now, after getting about 30,000 on them before the first failure. It's just weird, and frustrating.

some had porous castings. i have a box full if you need another one. free.

Thanks, John. I think I'm actually going to bite the bullet and put the Carrera kit in it. I'll do the Jerry Woods mod, putting the stop in the bottom, and call her good. A lot more spendy than free, but I like the long-term peace of mind that combination has to offer.

Is John Walker great, or what?

(OT, I know, but I couldn't resist!)