I just went through this on my 96 crown vic. Kept having noise, chirping, etc on a 3 month old NAPA belt.
I changed the pulley bearings out with no difference, so I took the belt back to NAPA and they traded me a new one - no more noise. I would say that you have enough miles on the belt that it could very well be the culprit.
Some comments:
- When you have the belt off, take a scotchbrite pad and clean up the pulley grooves - they can get debris in there that can contribute to belt slippage and noise.
- Don't buy a whole pulley if you can just swap out the bearing in the pulley. No need to pay $20 and up when a new bearing is $4 and very easy to get out. My CV has the same pulleys for tensioner and idler and they both take a 6203 sealed bearing. $8 and 10 minutes worth of work got me two "new" pulleys. Just look at the number on the bearing itself and see how the bearing is installed. Most times it's just pressed in there, but easy to remove/install with a socket and some careful hammer taps, a breeze with a small press.
- Agree that the cheaper belts seem to get glazed/harder quickly and don't seem to last as long as a better quality version.
- Kudos to our small town NAPA - they didn't even care about a receipt, just said that customer satisfaction was the priority and handed me a new belt. I like that.