If you beleive it's at the end of it's travel, what's going to happen as the belt stretches?

Thats my worry and problem - I either have to buy new gears or get the lengthened plastic spacer on the arm.

I would be willing to bet it's not the gears. I can't imagine gears wearing down to that level. My $$ is on the belt. What brand is it? Is it Porsche belt? I say get another and compare. Tell the parts shop that you have a situation with what they sold you and you need another replacement. Make sure its Porsche belt.
Raj

The belts a Contitech belt.

http://www.contitech.de/pages/produk...estung_en.html

I'd be interested to get a measuremt of someones car from the edge of the tensioner case to the end of the piston.

Rich

Stay away from Contitech belts, especially the bs belt. Too many documented failures!
Don't say you weren't warned. Pay a little bit more now or a lot more later. They have failed in less than 10k miles before. There goes your problem right there! They seem to work fine on bimmers, vw/audi but for some reason, don't hold up well on our cars.
Raj

Are you serious?? Everyone seems to use them overhere.

Whats recomended?

Rich

Porsche oem belts, never skimp out on them. Cheap insurance. They are Dayco last time I checked which was 2 months back.
Raj

My contitech BS belt broke at 20k miles, and it tangled into my timing belt. That one hurt my wallet.

Regardless, I think your belt is too long. I don't buy that about the gears wearing out. My '93 has 240k miles on it, and everything works perfectly with the timing belt and tensioner. I don't know how or why a belt can be too long, but it's possible. Remember, if your belt is indeed too long, and you band-aid it with a bigger white bung, your valve timing will never be right.

I've put 43k miles so far on Goodyear belts and intend to use them again. I got them through Advance Auto's online store.

What happened t the pictures?