Notes & Caution Overhaul

• Fabricate small tool, and carefully pry connector block upward. DO NOT bend connections. Remove stator from rear housing. See Fig 1.
  Fig 1: Removing Connector Block

  Courtesy of FORD MOTOR CO.
• Check brush length. Replace brushes if worn less than .250" (6.35 mm). Replace all damaged components.
• Use only high-temperature bearings when rebuilding alternator. Standard bearings will result in alternator failure.
• Clean rectifier base plate with a clean cloth. Apply a 3/32" (2.0 mm) wide by 3/4" (20 mm) long strip of Heat Sink Compound (ESF-M99G138-A) lengthwise across rectifier base plate.
• Rectifier is cooled by conducting heat directly into alternator rear housing. Failure to apply heat sink compound may cause rectifier overheating.
• Retain brushes in place by inserting a 1 3/8" piece of stiff insulated wire into brush holder pin hole. Install nuts and washers in retaining slots of brush holder.
• Place a small amount of waterproof sealer over brush pin hole. Do not use silicone sealer. Rotate pulley to check for freedom of movement.

Fig 2: Exploded View of Alternator With Internal Regulator

Courtesy of FORD MOTOR CO.