2004 6.0 belt??
 

What all has to come off to replace the belt I am puting a motorcaraft back on?

Really nothing has to come off, it helps to take the top part of the schroud off so you can get to it alot easier, the top piece will come off with a couple bolts and maybe a couple screws holding the 2 pieces together. The rubber seal will have to be pulled out some to get it out of there. It is alot easier with 2 people and it is easier if you remove the tentioner but not neccesary, it saves time in the long run because it is a pain to get the belt behind it.

The aft shroud is a clip on, but be careful you don't break the clips. If you have a SINGLE alternator, you will be able to see the tensioner release thingy, it's a 1/2" socket drive on the passenger side. Using a ratcheting torque wrench (for the length), set the load high so as not to fight it, rotate the head, feel it into the slot, push, and viola, tension is off the belt. I didn't try to remove the belt or the wrench because I was only doing an alternator change so I just eased the wrench back towards the fender and left it there until I was done with the swap.

Bob's method is to man handle the belt until it comes off of the alternator. This is crude, but effective as well.

If you can't get to the tentioner you can loosen the alternator and let it tilt forward and take the belt off that way, we found that to be the easiest way, loosen the bolts up then hold the alternator down with your hand, its pretty easy to hold down, then remove bolts by hand and then let it tilt forward and it is pretty easy to remove the belt then. I used to man handle the belt until I had to change a AC pulley at a rest stop and did it this way, I think its easier then using the tentioner,

I can get to the tentioner no problem done that befor but i did not see bolts that held the shroud together it all looked like one piece to me?

You didn't see any bolts on the shroud because the aft shroud we mentioned uses clips. :w2:

No mine looks like one round piece. Maybe i am looking at it wrong i will take another look, thats why i was a bit confused

Karls03 is talking about the little one on top of the fan shroud, the clips are in the picture below. The other one mentioned is the stator, which is a two piece unit that sits between the fan shroud and motor. The stator is bolted to the motor and can be separated in half so the top half can be removed, but for replacing the belt, it's not worth the headache of separating the stator.

Attachment 38369

There is a tab on the tensioner and you just push it in and pull the belt up with the other hand. Takes a lot of strength, two people can do it real easy. I have done this with no tools by myself.

ive got a special tool I use to pull it from underneath the truck, its a two man job though at least for me..