Ford 7L7Z-10346-B Alternator Assembly

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Detach the cable from the negative terminal of the battery. Unplug the electrical connectors from the alternator. Remove the drivebelt. On 4.6L engines, remove the ignition wire assembly from the 1ke manifold area. Remove the bolts and separate the alternator from the engine. On 2005 and later 5.4L engines, remove the four bolts and the mounting bracket above the alternator, then remove the i lower alternator mounting bolts. Installation is the reverse of removal. Alter the alternator is installed, install the drivebelt and reconnect cable to the negative terminal of the battery.

Before disassembling the alternator, ensure that replacement parts are available. Remove the alternator and set it on a clean workbench. Remove the four voltage regulator mounting screws to detach the voltage regulator/brush holder assembly. Lift the assembly from the alternator. Detach the rubber plugs and remove the brush lead retaining screws and nuts to separate the brush leads from the holder. Note that the screws have Torx heads and require a special screwdriver. After noting the relationship of the brushes to the brush holder assembly, remove both brushes, being careful not to lose the springs. If installing a new voltage regulator, insert the old brushes into the brush holder of the new regulator. If installing new brushes, insert them into the brush holder of the old regulator, ensuring the springs are properly compressed and the brushes are properly inserted into the recesses in the brush holder. Install the brush lead retaining screws and nuts. Insert a short section of wire, like a paper clip, through the hole in the voltage regulator to hold the brushes in the retracted position during regulator installation. Carefully install the regulator, ensuring the brushes don't hang up on the rotor. Install the voltage regulator screws and tighten them securely. Remove the wire or paper clip. Finally, install the alternator.

Insert a short section of wire, like a paper clip, through the hole in the voltage regulator.

Remove the drivebelt.