How do you replace serpentine belt on 2004 ford diesel?

Answer 1

Depends on if your truck is equipped with automatic tensioner or not. I just did mine this weekend. It has the automatic tensioner with a single standard duty alternator.

To remove the old belt you must release the tension. There was no way to get a 1/2" ratchet on the tensioner (fan shrowd in the way). However, there is another way to loosen the tension on the belt. Ford included a small metal clip on the tensioner to lock it in the retracted position. I retracted it by pulling on the belt just below the alternator. Since I was working alone I had to use my left hand to pull the belt and with my right hand I used a broomstick to push the clip into the locked position. It does take some strength to do this but I am of average size and strength and I was able to get it first try. If you have some assistance you can use 2 hands to pull the belt while the assistant locks the tensioner so it would be easier.

IMPORTANT NOTE: Before you remove the old belt make sure you take good notes on how it is routed. If you can't get the new one back on correctly your truck is dead in the water and will require a house call from someone who can get it back on or a tow to your mechanic.

Once the tensioner is locked you just have to work through the painstaking process of working the belt off of all the pulleys and pulling it out. Takes some work because of the low clearance between the fan shrowd and the front of the pulleys. I removed the bottom 2 fan shrowd mount bolts to get a little additional clearance. Additionally I used a small thin piece of wood to help work it through the tight spots. I used a piece of shim shake (wooden roofing shingle). A piece of trim would probably work as well.

To install the new belt, from the top I fed it underneath the alternator and across the front of the engine. Then from underneath I just started with the pulleys on the driver's side and worked toward the passenger side. I tucked it around each pulley one-by-one until I had it back in place.

Double check the routing of the belt and make sure it is correct and properly lined up on all the pulleys. When you are sure it is correct, just pull on the belt underneath the alternator. The metal clip holding the tensioner should automatically disengage to release the tensioner and take up the slack in the belt.

Start the truck and run it for 10 mins to properly break-in and seat the belt. Double check the tension when you shut it off.

Thephoneguy added: The idea was accurate however my neighbor was working and I had to do it myself. I grabbed a click click strap on and attach the belt to it and to an inner side of the truck right where the hood hinch enters when you close the hood. I started putting tension on the strap until i could slide a huge screwdriver in between the belt and the alternator base pulling stronger with one hand. at the same time and with muy other hand i grabbed the broom stick and managed to move the tension belt clip in (this clip goes up clockwise) and that's it the belt is loose. I only wanted the belt loose to replace my alternator. Thanks anyway because your procedure help me modify it to fill for my needs.