Well, I was unable to get the OAD off. When I pulled the cover about a tablespoon of dust (rust or metal filings) fell out. The pulley was certainly eating itself alive. The shaft didn't seem rusted, but I could not break the pully loose with the special tool. I was putting so much torque on the tool I was afraid I would either break the tool (as I've read several others have done) or shear the shaft. I basically ran out of time on this one. Put the whole thing back together Sunday afternoon and took it into the shop to today to have a new mopar unit installed. Noise gone. BTW-if you have the Lifetime warranty the tensioner is a freebie.
I'm taking the family on a long holiday trip and I needed to get it done. Maybe if I had more time I would have tried again with a new unit on hand in case I destroyed the old one. I have the miller puller and a brand new OAD if someone wants them. PM me.
Last edited by happydaddy; 11-14-2011 at 10:03 PM.