Dang, that sucks. The Novak kit I used has worked flawlessly going on a year now.
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one other thing I found was the tensioner pulley that came in the kit did not have the bearing pressed in all the way. It would not turn when installed. The sharp radius on the pulley needs to be facing the engine and the bearing needs to be pressed flush to that side for it to have clearance and not lock up when you torque the bolt down.