1996 alternator removal

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Pablo sho

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My battery light has been coming on for some time. Usually goes out after driving a few miles. Right now I'm replacing the AC pump and front engine mount so might as well replace the alternator.
Does anyone have any tips to get the top bolt out? Thanks Paul
 

Pablo sho

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Thank you! Removing the cowling and fuel lines made it possible. All bolts are out but it's getting hot so maybe later I will get the wires off and get it out. Good thing I was under there as someone didn't put the cotter key in the tie rod. Parts won't be here for awhile anyway.
 

GEN 3 SHO FAN

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This bolt isn't easy to reach. Better with the surge tank removed. At least, you can remove black plastic sheild containing the cabin filter (upper and lower parts). Upper one have some plastic and steal retainers and lower one have around 3-4 small screws.

You already have 2 choices there but I have another one. Jack the front passenger wheel and retreive it. You can turn the wheels to the right to help.

Don't mess with brake lines, front swaybar and subframe.

Just unbolt the tie rod end from the knuckle (bolted with a lock under).

If you're a good tetris gamer, you will be able to retreive/enter the alt by the openning in the wheel well where the tie rod pass. (I did 2 times, you have to rotate it a lot.) Pass it with caution as the brake line is very near.

Before fixing new alt, I suggest you to find a bolt identical to the 2 lower ones (without stud at the end) because this bolt will be a lot easier to bolt /unbolt next time with a wrench. The stud is there to hold a ground wiring (motor to frame) and it can placed at the lower part of a surge tank support (2 verticals). The bolt can be found on any Taurus with a 3.0 Vulcain engine with the alt on the top, it's the same bolt.

It's doable with 2 hands but if you're able to have 2 addtionnals to "guide" the alt in place while you put it in place (once it passed), it will cost less time (1 person at the wheel and another at the top).

Don't give up, I like your motivation !
 
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Pablo sho

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Motivation....lol... luckily I have other vehicles to drive.
About 10 years ago I discovered I am a professional shade tree mechanic as I looked for the best tree to work under before starting my project. It is afternoon shade you need to find as it's generally cool in the morning and the sun will feel good.
As far as removing it I have not got that far. Maybe tonight if I get motivated so thank you for the advice.
 

GEN 3 SHO FAN

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If you try to find this bolt, you can also have a chance to find a good rebuilt alt on a Ford Expedition (near same years) for around 30-35$, they are on the top of engine and easy to retreive.
 

Pablo sho

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Thank you. Good info but I already ordered a new one.
One of you should come work on this pos or take it off my hands. We have a love/hate relationship going on.
 

luigisho

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I had enough wrenching on those to last me. It was a reliable car relative to the earlier SHOs I have owned but when you have to wrench on them it's no room to do anything anywhere.
 

98SF19

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I was able to reach in with a stubby wrench and break the top one loose. As I recall, it required a level of exertion I didn't think I had in me. I think that just getting each bolt to budge at first, then going to each one and giving a 1/4 turn or so is best. Otherwise, by loosening one very much, it binds the others. That's probably what happened to me.

Yeah, fennagling that bastard out was a pita, but for some reason the reassembly wasn't as bad, though it's been several years now. This job was surpassed only by a recent run-in with removing and reinstalling my wiper assembly from inside the cowl. Reinstalling that thing nearly took my sanity.

Surely this isn't the original alternator . . .
 

GEN 3 SHO FAN

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I had enough wrenching on those to last me. It was a reliable car relative to the earlier SHOs I have owned but when you have to wrench on them it's no room to do anything anywhere.

I think it's better than a Gen 4 however... but it's another story.
 

98SF19

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modern truck and there is not a lot of space under the hood
With regards to late model F-150s that aren't lowered, if you're at least 6' 2", getting hands down in there isn't a big deal. My average height ass needs a step ladder, which I also use to wash/wax the roof!
 

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