ok, I think I understand. The rod came out without any resistance. It seems the tiny spring is not doing any kind of work at this point. Once I get the used tensioner I'll play around with it and see if there is anything I can do with the old one.
Thank you again and I'll provide an update in a few days.

 

It may be that your chain is stretched beyond tensioner adjustment at this point. Meaning that, the rod has gone out to the max and yes, at this point there is zero resistance or friction to pull it out of the slot where it seats.

 

I have the feeling it might just be the tiny spring not being in the right position because when the rod was in there, I could push it down without any kind of resistance (other than the one from the spring). I just don't know if I'll be able to push the tiny spring back into the correct location. Once I get the other tensioner I'll be able to understand exactly how it fits in there.
Thanks again Red Baron!

 

Yup if you could insert the rod without having to depress the ratcheting mechanism then a misplaced/misaligned spring could very well be the cause. If you had one of those surgery robots that cardiologists use then maybe you'd be able to get it back, but I don't think it'd be possible by hand. I know those scopes sometimes have little hook attachments so if you've got steady nerves I guess you might be able to repair it without taking the whole thing apart. Bragging rights if you do

Once you get the part you'll be able to get a sense of how it works

Unfortunately if the chain is stretched it'll be a moot point. Believe me, I understand the feeling of not wanting to take an engine apart...

 

I know we are kind of beating a dead horse, but if you were able to push in the rod with the big spring being your only resistance, then the lip from the finger spring must be broken.
I love the mystery going on now, but will find out soon.
Keep the spirits high and report back.

 

Red Baron/Tentacleslap, I received the used tensioner today and looks like you both are right.
Like you mentioned Red Baron , the chain must be too stretched and the old rod ran out of indentations for the latch to grab. The good news is that the rod on the tensioner I got (from a 1996 engine), has indentations all the way down. I wonder from what model on they redesigned it. The head of the rod is bigger as well.
IF I am able to insert this '96 rod, into my old tensioner, it should buy me sometime since I have a good 13mm worth of extra travel. The biggest challenge like you mentioned Tentacleslap, will be to do this while in the engine, from the small stator opening. Worth a shot. I just hope the old tinny spring stays in place once I depress the tab to allow the rod to go in. Having another tensioner definitely gave me a much better idea on how it works, and without even knowing or expecting it, I hope the solution to this issue since the rod has more indentations.
It is extremely hot here right now so I'll wait until it cools down a little to try this.
Please let me know what you all think. Thank you again for all your help!

 

That is a better rod design for sure with more indentations for adjustment.
Now the only problem I see, aside from moving the tab and spring not falling off, is the head of the rod might be too big/wide. The rod head has to fit behind the guide chain channel. You could reduce it to make it fit for sure, but make sure to do it with a cooling agent. You don't want to take the metal hardness/strength away produced by the heat of grinding it down.

 

Thank you Red Baron. The rod's head thankfully fits fine behind the guide.
I just tried to push into the spring loaded tab. I can't get it to go down far enough to jam the coathanger in there. I also tried with a thinner rebar wire but same thing. The spring looks in good shape and in the right position. I'll try again later on.


Update: I was able to jam the coathanger rod in there. Same technique, just better luck. Then I tried inserting the rod but my hands are too big. I had my 21 y/o son do it for me. I just taped the head of the rod to his finger and with the scope on the other he was able to slide it in there. Taking a break now.

 

Nice job. Your son just saved you a ton of work

Those scopes are a game changer. Being able to see makes all the difference

 

No doubt, I owe him big time.

Ok, the stator is in but not all the way. I tried tapping the shaft but looks like it is stuck at the bearing. I can screw the nut onto it and then crank it to bring it in. Is this what you've done in the past or should try something else?