Mercury FODZ-10316-A Regulator Assembly - Voltage

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To remove the alternator, set it on a clean workbench. Then, remove the four voltage regulator mounting screws to detach the voltage regulator/brush holder assembly. Lift the assembly from the alternator and detach the rubber plugs. Remove the brush lead retaining screws and nuts to separate the brush leads from the holder. 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 paperclip, through the hole in the voltage regulator to hold the brushes in the retracted position during regulator installation. Carefully install the regulator, making sure the brushes don't hang up on the rotor. Finally, install the alternator.

To detach the negative terminal cable of the battery, locate the voltage regulator on the right side of the engine compartment. Remove the battery or air cleaner duct to gain access to the voltage regulator if needed. Unplug the electrical connector from the voltage regulator and remove the mounting bolts and remove the regulator. Installation is the reverse of removal.

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.

Locate the voltage regulator on the right side of the engine compartment.

Remove the regulator mounting bolts.

Remove the four voltage regulator mounting screws.

Carefully install the regulator, making sure the brushes don't hang up on the rotor.