2022 Tellaro Altenator Belt Cuts Radiator Hose

[Mark54]

Has anyone had trouble with the serpentine belt modification for the Ballamar Altenator/Genrator on the Reliable Lithium option cutting the radiator hose? We have only owned our vehicle for 4 months and have cut through two hoses in 5,000 miles. If you own the Tellaro with the Lithium option you should check under the passenger side behind the front wheel for clearance. I think it might be a Thor Design flaw.

I have a Tellaro 20L, and it's very tight down there. Mine is ok for now, but someday I want to change it.
There is actually a recall/fix campaign on that setup, as they have had a lot of issues with it.
below is the document. It involves re-doing the plumbing and getting it out of the way. TMC factory should have it as well, dealer may not have a clue.

 

[beervanner]

Replacement of alternator belt

Thor told me the belt for this alternator assembly was a 470K-6, and I bought one, but having difficulty moving the tensioner enough to get it on. I'm using a belt tensioner tool I got from an auto parts place. Anyone on here done this? Tips would be appreciated.

I already took it to my usual car repair place and they wouldn't touch it because it was a custom assembly. 3 month wait at my RV dealership.

Thanks
2021 Thor Sequence 20L w/ 800Ah Lithium package.

 

[MCP-THOR]

Thor told me the belt for this alternator assembly was a 470K-6, and I bought one, but having difficulty moving the tensioner enough to get it on. I'm using a belt tensioner tool I got from an auto parts place. Anyone on here done this? Tips would be appreciated.

I already took it to my usual car repair place and they wouldn't touch it because it was a custom assembly. 3 month wait at my RV dealership.

Thanks
2021 Thor Sequence 20L w/ 800Ah Lithium package.

Interesting. The 470k-6 belt seems to be a 47" belt (per Autozone). The belt listed in the pdf doc that Mark54 attached in his post #121, which is the same doc I posted in #117 but with a different file name, calls for a 53.5" belt. Perhaps your layout is different, especially if that alternater/hose modification was not done on your Tellaro. I believe they did not start that revision until mid 2022. Also, I'm surprised that mechanic wouldn't touch it. You may want to find a good old fashioned shade tree mechanic.

Mike

 

[beervanner]

Thanks for the reply. I cut off the remains of the old belt and it measured 47". It seems to match up to the new belt. I just sent an email to Nations to see if they had any instructions for the tensioner.

My Sequence was one of the early models with Lithium, it was an add-on that I had to order. The belt is definitely brushing the radiator hose, but no leak yet. I also emailed Thor asking about that fix that was posted here.

 

[MCP-THOR]

Thanks for the reply. I cut off the remains of the old belt and it measured 47". It seems to match up to the new belt. I just sent an email to Nations to see if they had any instructions for the tensioner.

My Sequence was one of the early models with Lithium, it was an add-on that I had to order. The belt is definitely brushing the radiator hose, but no leak yet. I also emailed Thor asking about that fix that was posted here.

Good info and good luck with getting to a resolution. Let us know the outcome and how Thor responds regarding the "fix." Wondering if it might be covered by a TSB or recall.

Thanks,
Mike

 

[Mark54]

Thanks for the reply. I cut off the remains of the old belt and it measured 47". It seems to match up to the new belt. I just sent an email to Nations to see if they had any instructions for the tensioner.

My Sequence was one of the early models with Lithium, it was an add-on that I had to order. The belt is definitely brushing the radiator hose, but no leak yet. I also emailed Thor asking about that fix that was posted here.

I use a Ram Business Link Dealer, who will do anything I ask- incl. anything w/the UHG- do you have one near you?
It could be just my dealer tech too- he's awesome about that sort of thing.
Otherwise start asking around- mobile RV techs as well? Good luck!

 

[HighhillThorman]

Have you contacted Thor? What did they say? That should be your first call.

Contacted them twice. Sent the wrong hose first time and no response the second time,

 

[HighhillThorman]

Stainless Steel elbow

View attachment 38976

1/16 steel mandible insert solution

Glenn,
Could you tell me where the parts are available for your modification with the stainless steel elbow. It may void the warranty but I'm 87 years old and don't have a lot of time to waste. Thank you.
Tom

 

[GlennC-THOR]

What type of vehicle are you driving?

 

[16ACE27]

What type of vehicle are you driving?

From his original thread:

My Thor Tellero has had a leaky radiator hose since I purchased it in June . The heavy duty alternator installed by Thor causes the Ram standard hoses to not fit and Thor Motors has not been able to provide the correct hose for nearly six months. Has anyone else had this problem or know where I can get the proper radiator hose. I haven't been able to take a long trip since I bought it.

 

[GlennC-THOR]

The issue I had was unique to the Thor Tellaro 20L with a Lithium Battery 200AH System upgrade. Thor modified the serpentine belt when they added a second altenator to charge my batteries. That resulted in the radiator hoze being cut thorough by the modification. My fix involved a new metal fitting from thor as well as a smaller diamater hose and a technician flown in by Thor to install it.

If you have a 2016 ACE you can probablly just look at the hose and get a replacement at Auto Zone or Advanced Auto or any local auto repair shop. If you can have any mechanic remove the hose and drain the coolant you can probablly just walk the part into any auto parts store and match it and have it reinstalled and refill your coolant. Maybe around $200 with parts and labor if you can find an honest mechanic.
You canget stainless mandibel elbows or parts at these stores; however if your belt comes into contact whih them it will shred the belt over time instead of cutting your hoze.

Good luck!

 

[16ACE27]

The issue I had was unique to the Thor Tellaro 20L with a Lithium Battery 200AH System upgrade. Thor modified the serpentine belt when they added a second altenator to charge my batteries. That resulted in the radiator hoze being cut thorough by the modification. My fix involved a new metal fitting from thor as well as a smaller diamater hose and a technician flown in by Thor to install it.

If you have a 2016 ACE you can probablly just look at the hose and get a replacement at Auto Zone or Advanced Auto or any local auto repair shop. If you can have any mechanic remove the hose and drain the coolant you can probablly just walk the part into any auto parts store and match it and have it reinstalled and refill your coolant. Maybe around $200 with parts and labor if you can find an honest mechanic.
You canget stainless mandibel elbows or parts at these stores; however if your belt comes into contact whih them it will shred the belt over time instead of cutting your hoze.

Good luck!

This has nothing to do with my ACE. You asked HighHillThorman what vehicle he had - I provided a quote from his original thread describing his vehicle and issue.

 

[GlennC-THOR]

Gotcha...I got those thread crossed. The problem on my Tellaro (assuming you have the same Lithium Configuration) is their addition of the second altenator. If in fact you have that they need to send you a replacement kit which includes a new smaller diamater radiator hose as well as a new metal custom pipe that accomdates their modification. If you simply replace the hose (which I did) the second hose will be cut as well. Thor is well aware of what they need to send you. In addition, if still under warranty they have to provide you the parts and the labor for install. They made the correction on all their 2023 B-Vans with the Lithium Battery options so they new the original conffiguration was wrong. I would also ask them to provide a new Serpentine Belt. The belt is not a standard MOPAR part and made by another vendor.

Again, I would tell them you need the new replacement kit for the radiator hose being cut by their modification.

 

[HighhillThorman]

Thanks for the update on the repair. Maybe there is some hope yet.

 

[beervanner]

I still haven't fixed this, since I haven't been camping much anywhere without hookups. It's driving me crazy though, I tried again today to fit the 47" belt on there and I just can't get it. Mine is definitely the Nations kit, not the CW Mill kit. Now I looked on the Nations site and they sell a 475-K6 belt for the kit, which is 58".
I'm sure the old belt was 47", I still have it.

 

[TellaroMT]

I didn't want to create a new thread, but this thread has been helpful. Not sure if others have had a similar issue, but my heater return hose is also getting cut. I ordered a new one (along with a lower hose) and plan on putting my engineering hat on and "fix" this. It's sad that Thor didn't test/research/use this layout themselves. You can see a pinhole coolant squirt in the pic.

 

[TellaroMT]

Here's the 2023 fix to clear the belts/hoses. Two different angles

This looks like it has the Nations tube which my 2022 has. The thing is it still slit the hose a bit.