Re: my serpentine belt has about 2inch's of slack in it....
Wrong size belt is a possiblity or the tensioner pulley was installed incorrectly alot of time what people dont understand is that before u remove a belt you ned to measure the tension before loosening pully because that is going to be your stepping stone for new installation if the tensions are not exact it can throw off the tension causeing dammage to the pulley system make sure your belt tensioner is correct and is tensioned to the proper plbs by either your locl autoparts store or your owners manual
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The belt is tensioned with a spring loaded pulley on an arm. To ID this part start the engine and watch the belt go around the pulleys, when you gun the engine the belt tensioner pulley will jitter to adjust the slack.
You could have a bad or worn serpintine belt. When you replace it make sure all the pulleys are rotating freelyi.e. air compressor, alternator, tensioner idler & power steering pullies to make sure all of their bearings are running freely. Good luck!
Click on the following free direct Link. It has the correct Serpentine/Drive Belt Diagram for your 2004 Ford Freestar. You either have the 3.9L or 4.2L V6 Engine. I am not sure what Engine options (AC/No AC, etc.) you have. If this Diagram is not correct: check on the underside of your Hood for the correct Belt Diagram. However the below "How To" remains accurate.
"HOW TO": Standard Rules to Removal the Serpentine Belt with an Automatic Tensioner: 1. Find the Tensioner(s). (See Diagram on Link) 2. Using a Serpentine Belt Tensioner Tool, Or Wrench OR Ratchet, Rotate/Move the Tensioner USING THE AVAILABLE NUT (on the Pulley or Arm Base) OR the OPENING (3/8ths or 1/2 inch square opening) rotating the Tensioner Pulley/Arm - moving it away from contact with the belt and towards the area where the belt is not in contact with the Tensioner Pulley. The Tensioner is spring loaded, and is hard to rotate/move. 3. Remove the loosened belt off one of the other more easily accessed Pulleys. 4. DO NOT quickly release the Tensioner, but gently allow the Tensioner to rest in its closed position.
Standard Rules for Installing the Serpentine Belt with an Automatic Tensioner: a. Pick a Pulley that is most easily accessed. This will usually be on top. This will be the last Pulley that the belt will go on. b. Using the Diagram: Install the new Serpentine Belt on the remainder of the Pulleys....over, under, left right. c. Using a Serpentine Belt Tensioner Tool or Wrench or Ratchet Tool: Rotate/Move the Tensioner Pulley/Arm "away" from Belt contact area on the Tensioner. This spring is pretty hard and with a new belt, it will be even harder to install. Rotate/Move this to as-close to the maximum allowed inorder to have enough slack in the belt to get it up and over the last pulley. d. Using your other hand - Pull the Belt up and over the Last remaining Pulley. e. Before releasing the pressure on the Tensioner, visually inspect the remainder Pulleys and the Belts' Positioning on them. Let me know if this helped, or if you have additional information questions. Feel Free to contact me at FixYa.com!
Use a wrench on the bolt. Slowly turn counterclockwise until there is enough slack to remove the belt. Hold in that position (if you let go the tensioner will automatically apply tension again). Remove the belt.
Do not fully remove the bolt as the tensioner will come apart. Just release the tension to the point where the belt is loose.
the serp belt is driven by the crankshaft pully and also has a tensioner may i suggest you check the crank pully it mayhave parted at the rubber damper and is spinning off line/back and forth also check the tensioner that runs on belt it may have failed or come loose
Crank the tensioner to get some slack in the belt and slide it off the uppermost, most easily accessible pulley. Remove the old belt. Route the new belt in accordance with the belt routing diagram and crank the tensioner the same direction as before to begin getting the belt over the uppermost pulley. Slide a screwdriver under the belt and over the pulley to leverage the new belt on. Release the tensioner and check for belt tautness. If the belt is loose, you've either purchased the wrong size or have misrouted the serpentine belt.
normally you can take a 1/2inch breaker bar and insert it in the hole on the tensioner pull down and take the belt off the alternator and also try autozone.com to see if they have your car listed for diagrams pictures and step by step instructions if your car is not listed then try your local library they have all the car manuals and even copy them for you