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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!
All you need is a 13mm boxed end wrench. The tensioner pulley is the one all the way on the bottom towards the rear of the van. You can reach it under the van. Slide under the van in front of the passenger front tire and you will wee the pulley. Put the wrench on the bolt and pull towards you to release the tension on the belt.