Flatlander thanks for the tip, that would have probably been my next mistake.
yeah what Flatlander said. It's REALLY easy to shove it down into the receiver in the case and... well look at the end of the tensioner -- see those two little spring-off "arms" at the sides? These provide a bit of side-side movement control as natural spring levers. BUT if you shove the tensioner it at a tiny bit of an angle and just think, "Oh well the slot is a snug fit, so I'll add a couple lbs. of muscle," what can happen is one of those little arms can snag on the top lip of the slot, and bend outward... and if its the side where the primary chain whirls right by about 1/4" to the side of it, well, you can imagine what ensues....
To ensure this doesn't happen, drop the drain pan, position the adjuster properly since you can now see it slide into place