Here's the Andrews roller chain upgrade for the engines that now run the problematic cam chain tensioners. It replaces the old style tensioners with the hydraulic chain tensioner used in the newer 96 TC engines.
This conversion eliminates the cam chain tensioners that wear away and disintegrate with the final result in damaging the engine.


http://andrewsproducts.com/PDF_files/Cams88_99-06chain.pdf

I wonder how much it would cost to have this installed?

The cams come from Andrews for now and the rest from the HD dealer. They should be able to give you a price for parts.

Wouldn't it be a wise choice to go with gear drive cams at this time?

Wouldn't it be a wise choice to go with gear drive cams at this time?


Gear drives will not be as popular as the roller chain conversion when you take into consideration the excessive run out on the shafts in some of the motors. Excessive run out makes for some noisy gear drives and since the start of the new chain tensioner here. it just about eliminates the older cam tensioner problems.

Doesn't the roller chain also have a nylon block as part of the tensioner assembly? Have they had any issues with it?

Yes, it has a nylon block as opposed the composition blocks on the older ones but look at the size of it compared to the older tensioners. Also it is oil pressure driven against the chain where the older chain tensioners were spring loaded, possibly the downfall of that system.

Also notice the contact point and how it rides against the chain too compared to the older ones.