Can you put a new spring in the tensioner housing piece? Get a little bit longer belt? Mine is so freaking tight I can barely the belt on, and the tensioner makes cracking sounds like a bolt does when it's real, real tight when I turn it. I called Vortech and the tech guy knew nothing and was rude on top of that. That's twice I've called them and gotten that. The sales guy was alright, and he gave me the stock Ford part number, but I haven't checked yet to see if that's what's already on there, I expect it is.

 

Oh. Well I used a big foot long adjustable and it was a lot easier. A mechanic told me he doesn't even bother with a 3/8 drive with the tensioners, he uses a 1/2.

edit: When I rebuilt it I found that the low speed bearings were just fine. They would be what would be messed up if too much tension was going to hurt something; so I'm not worried about a tight belt now. Also the low speed bearings are only about $20 for both. :edit