I got the auto parts store to replace the failed beck arnley tensioner with one made by ITM. I attached a picture of the culprit. you could push in the pin with your finger! The parts store tells me even factory mitsubishi parts are bought from the lowest bidder, so they don't think there will be any difference. anyway, got it all back together, runs great!

thats good info on the RBT - to not push it in too fast and damage the bladder - I didn't know that. I managed to install the new tensioner with pin in and adjusted the torque on the tension pulley so that after hand cranking 4 turns the pin could easily be removed and inserted again - so never had to push it back in.

btw, the worst part of disassembly in the past was getting the AC compressor off to remove the compressor bracket so you could remove the Accessory bracket. I found that using a 13mm ratchet combination wrench made it pretty easy - in case any of you have to do this job...

thanks for your advice, guys! btw, that Aisin kit sounds great with good price - I will look into that one next time!