I am ay a lost here. I have a 2003 5.9 and about once a year my drive belt get slit by about 1 or 2 groove. I asked the dealer to inspect this last May and it just did it again. They checked the pulley alignment, the pulley wear, the tension,etc...

Any idea of what might cause that other than that?

 

that sounds kind of strange.


I would suspect a fauty pully, bearing, or tensioner..

could also be that it was installed just a smidgen crooked.

 

Not sure that this will help, but worth a try....
For 2003-2005 (up to 6/2/05) Diesel Rams: If ordering a tensioner due to a misaligned/frayed/squealing belt, the tensioner is most likely NOT AT FAULT for these conditions. Examine the tensioner for proper alignment and smooth operation and if it appears OK, order the new OAP (Overrunning Alternator Pulley, P/N 05183490AA) to repair the condition. Only order the tensioner if it is damaged and not operating within the acceptable range found in between the tang and the housing stop. If the belt is not damaged please re-use the belt where possible. See TSB 09-004-06 for further information.

 

The idler pulley (smooth face, no ribs) tends to wear a little more on one side then the other and can cause the belt to rub the edge of one of the ribbed pulleys.

 

When I first got the truck I had the belt jump part way off one of the pullies and it was running this way, but had a different sound. I shut the truck off and repositioned the belt back onto the pully and it has been good ever since. You just might want to make sure that the belt is on all of the pullies correctly.