I installed the gates kit today. Tensioner and idler pulley were easy to install. I used a 15mm stuby wrench to remove the tensioner nut under the alternator. I tried in vain for hours to install the dam belt. Finally I called Midnight Auto to ask for help. After being disconnected twice I was told sombody would email me in 4-5 business days! With nothing else to do, I played on the internet looking for help with the belt and I found these helpful instructions. Several of these ideas are good ones, and worth passing along. 10 minutes later the job was done.
Gates belt instructions:
Just installed the Gates 38379K for the 3.8 engine. Idler replacement was a breeze. Tensioner was a bit tricky. I went from under the car with a 3/8" "wobble" adapter I found at Sears and a 6" extension. Made that part a lot easier. Stuff a bunch of shop rags against the front of the tensioner to keep the key lined up when tightening.
The belt is a bear to install. I found the easiest way to do it is to seat all pulleys except the water pump. use a small plastic spring clamp on the crankshaft pulley and belt to keep the belt from slipping off. Put a long 15mm wrench on the tensioner, then put the old belt on the wrench and let the excess belt dangle off the front of the car. Put your foot in the belt loop and push down to move the tensioner, and slip thebelt over the water pump pulley. Since it is the only one without a lip or grooves, it slips on much easier than all the other methods I tried. DON'T FORGET TO REMOVE THE CLAMP BEFORE STARTING THE ENGINE!
The van seems to be functioning well, and this kit is a lifesaver. I hated trying to thread the belt back on every time it slipped off.
I still urge everybody with this problem to file a complaint with NHTSA. They are the only ones who can put pressure on Chrysler to fix this.