Yeah, i've pulled apart a spare tensioner tonight as i was thinking of not using the circlip at all but then as far as i can see it's just gonna over-tension the chain which isn't gonna be any good.

I think what happens is when you force it back in it stretchs the circlip, which was probably why it was fine the last time i did it but now it's just too big to jack out from the grooves in the outer bit of the tensioner, i think it'll probably be ok once running as oil pressure will build up and jack it out. Although it might not, and it might bend valves and i can't be arsed with taking the damn head off again!

Only problems now are; do ford still stock it, will me dealer [who is fecking miles away from here] have it in stock and will it cost an arm and a leg!

I understand new ones pop up lovely, i.e. i can push down on the plunger and it'll go click click click click all the way until the chain is at the right tension, is that correct?