You can get Motorcraft belts at your local Ford parts counter. I don't know what to tell you about the length, though. If the Ford parts guy is good, he should be able to tell you what you need.
Where would I get a Motorcraft belt at? Also, is it a problem that I need a different-from-stock length (111.5 inches)?
What kind of belt is the new one? I've always had good luck with the Goodyear Gatorback belts.
I have the exact same problem, but on a 97 Plymouth Voyager minivan.
Like you, I replaced the idler pulley and the tensioner pulley, but no improvement. Belt dressing makes the noise go away, but only for a minute or two.
I also installed a new Dayco belt about two weeks ago. I have come to the conclusion that the Dayco belt may be the cause. I will find another brand (preferably a Gatorback) and report.
...Goodyear Gatorback belts...
Its the tensioner and it was a common problem a couple years ago. The reason being the tensioner is made out of aluminum and the factory ford design is such that over time the aluminum will fatigue and slightly bend causing it not to sit completely perpendicular to the belt. Replace the tensioner with a new one. Not sure, but I'd expect the aftermarket makes a factory steel replacement.
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