Mercury F1DZ-10C359-A Regulator And Brush Holder Assembly

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To remove the alternator, set it on a clean workbench. Then, remove the four voltage regulator mounting screws and detach the voltage regulator/brush holder assembly. Next, detach the rubber plugs and remove the brush lead retaining screws and nuts to separate the brush leads from the holder. After that, remove both brushes, ensuring not to lose the springs. Install the brushes into the regulator, making sure 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 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. Finally, install the voltage regulator screws and tighten them securely.

Having removed the alternator, put it on a clean workbench. Unfasten four screws that hold voltage regulator in place so as to remove the voltage regulator/brush holder assembly. Remove rubber plugs and brush lead retaining screws and nuts to separate brush leads from holder. Ensure springs are not lost because both brushes are removed. The brushes have to be installed back into the regulator in such a way that they are properly fitted into the recesses of the brush holder. Secure brush lead retaining screws and nuts tightly. While fixing the regulator, you can use a wire or paper clip to hold brushes in retracted position. Be careful when installing the regulator so that its brushes will not stick to the rotor.

Check the availability of a new regulator before proceeding. On some models it may be available only as a new unit with a new alternator. To remove, first remove the alternator. Set the alternator on a clean workbench. For 4.0L pushrod V6 models, remove the four voltage regulator mounting screws and detach the voltage regulator 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 the relationship of the brushes to the brush holder assembly, then move both brushes. Don't lose the springs. If you're installing a new voltage regulator, insert the old brushes into the brush holder of the new regulator. If you're installing new brushes, insert them into the brush holder of the old regulator. Make sure the springs are properly compressed and the brushes are properly inserted into the recesses in the brush holder, then install the brush lead retaining screws and nuts. For 4.0L SOHC V6 and 5.0L V8 models, remove the rear cover mounting screws and detach the rear cover from the alternator. Remove three voltage regulator mounting screws and detach the voltage regulator from the alternator. The alternator brushes on these models are soldered to the voltage regulator, therefore the voltage regulator/brush assembly must be replaced as a unit. To install, insert a short section of wire or straightened paper clip, through the hole in the voltage regulator to hold the brushes in the retracted position during regulator installation. Carefully install the regulator. Make sure 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.

To detach the cable from the negative terminal of the battery, locate the voltage regulator on the right side of the engine compartment. The external voltage regulator is placed in the corner of the engine compartment and then unplug the electrical connector from the voltage regulator, and remove the regulator mounting bolts. The installation is the reverse of removal.

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