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    Lincoln Blackwood, Ford F-Series Pick-ups, Lincoln Mark LT 2001-2006

    Alternator

    Print

    Diagnosis & Testing



    Dual Alternators

    WARNING
    To prevent damage to the alternator, do not make jumper wire connections except as directed. Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the key on or off. A short circuit will result and burn out the diodes.


    NOTE
    The battery posts and cable clamps must be clean and tight for accurate meter indications.

    1. Turn off all lamps and electrical components.
    2.  
    3. Place the vehicle in NEUTRAL and apply the parking brake.
    4.  
    5. Carry out the Load Test and No-Load Test according to the following component tests:
    6.  

    Alternator On-Vehicle Test-Load Test
    1. Switch the tester to the ammeter function.
    2.  
    3. Connect the positive and negative leads of the tester to the corresponding battery terminals.
    4.  
    5. Connect the current probe to the alternator B+ output lead, circuit 36 (YE/WH).
      NOTE
      Make sure to disconnect the alternator that is not being tested.

    6.  
    7. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the alternator. The alternator output should be at least 87 amps.
    8.  
    9. With the engine running, turn the A/C on, (if equipped) the blower motor on HIGH and the headlamps on high beam.
    10.  
    11. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. Backprobe the I circuit at the alternator connector (connector plugged in) and measure the I circuit voltage. If the voltage is less than 2 volts, install a new alternator. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests-No-Load Test, in this section. If the voltage increases as specified, the charging system is operating normally. Proceed to the following battery tests.
    12.  

    Alternator On-Vehicle Test-No-Load Test
    1. Switch the tester to the voltmeter function.
    2.  
    3. Connect the voltmeter positive lead to the alternator B+ terminal and the negative lead to ground.
    4.  
    5. Turn all electrical accessories off.
    6.  
    7. With the engine running at 2,000 rpm, check the alternator output voltage. The voltage should be between 13.0 and 15.5 volts.
    8.  

    Single Alternator

    WARNING
    To prevent damage to the alternator, do not make jumper wire connections except as directed. Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the key on or off. A short circuit will result and burn out the diodes.


    NOTE
    The battery posts and cable clamps must be clean and tight for accurate meter indications.

    1. Turn off all lamps and electrical components.
    2.  
    3. Place the transmission in NEUTRAL and apply the parking brake.
    4.  
    5. Carry out the Load Test and No-Load Test according to the following component tests:
    6.  

    Alternator On-Vehicle Tests-Load Test
    1. Switch the tester to the ammeter function.
    2.  
    3. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
    4.  
    5. Connect the current probe to the alternator B+ output terminal, circuit 36 (YE/WH).
    6.  
    7. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the alternator. The alternator output should be at least 87 amps.
    8.  
    9. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
    10.  
    11. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests-No Load Test, in this section. If the voltage increases as specified, the charging system is operating normally.
    12.  

    1. Switch the tester to the ammeter function.
    2.  
    3. Connect the positive and negative leads of the battery tester to the corresponding battery terminals.
    4.  
    5. Connect the current probe to the alternator B+ output terminal, circuit 36 (YE/WH).
    6.  
    7. With the engine running at 2,000 rpm, adjust the tester load bank to determine the output of the alternator. The alternator output should be at least 87 amps.
    8.  
    9. With the engine running, turn the A/C on, the blower motor on high speed and the headlamps on high beam.
    10.  
    11. Increase the engine speed to approximately 2,000 rpm. The voltage should increase a minimum of 0.5 volt above the base voltage. If the voltage does not increase as specified, carry out the Alternator On-Vehicle Tests-No Load Test, in this section. If the voltage increases as specified, the charging system is operating normally.
    12.  

    Alternator On-Vehicle Tests-No-Load Test
    1. Switch the tester to the voltmeter function.
    2.  
    3. Connect the voltmeter positive lead to the alternator B+ terminal and the negative lead to ground.
    4.  
    5. Turn all electrical accessories off.
    6.  
    7. With the engine running at 2,000 rpm, check the alternator output voltage. The voltage should be between 13.0 and 15.0 volts.
    8.  

    1. Switch the tester to the voltmeter function.
    2.  
    3. Connect the voltmeter positive lead to the alternator B+ terminal and the negative lead to ground.
    4.  
    5. Turn all electrical accessories off.
    6.  
    7. With the engine running at 2,000 rpm, check the alternator output voltage. The voltage should be between 13.0 and 15.0 volts.
    8.  

    Removal & Installation



    4.2L Engines
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Drive belt
       
      Alternator electrical connectors
       
      Alternator stator and voltage regulator connectors
       
      Alternator battery cable nut and the cable
       
      Alternator bolts and the alternator

      Click image to see an enlarged view

      Fig. Alternator mounting-4.2L engine

       

    4.  

    To install:

    1. Install or connect the following:

      Alternator and tighten the bolts to 35 ft. lbs. (47 Nm)
       
      Alternator battery cable and the nut
       
      Alternator stator and voltage regulator connectors
       
      Alternator electrical connectors
       
      Drive belt
       
      Negative battery cable
       

    2.  

    4.6L & 5.4L Engines
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Drive belt
       
      Alternator bracket bolts
       
      Ignition wire from the alternator
       
      Alternator bolts and the alternator
       
      Alternator electrical connectors
       
      Alternator stator and voltage regulator connectors
       
      Alternator battery cable nut and the cable

      Click image to see an enlarged view

      Fig. Alternator mounting-5.4L engine, exc. Lightning. 4.6L similar

       

    4.  

    To install:

    1. Install or connect the following:

      Alternator battery cable and the nut
       
      Alternator stator and voltage regulator connectors
       
      Alternator electrical connectors
       
      Alternator and the bolts, tighten to 18 ft. lbs. (25 Nm)
       
      Ignition wire from the alternator
       
      Alternator bracket bolts and tighten to 89 inch lbs. (10 Nm)
       
      Drive belt
       
      Negative battery cable
       

    2.  

    6.0L Diesel Engine
    Dual Alternators
    1. Before servicing the vehicle, refer to the Precautions Section.
      NOTE
      The following applies to the secondary alternator. For primary alternator, see the Single Alternator procedure.

    2.  
    3. Disconnect the batteries.
    4.  
    5. Remove the coolant fan.
    6.  
    7. Rotate the accessory drive belt tensioner clockwise and remove the drive belt from the alternator pulley.
    8.  
    9. Remove the nut and position the alternator B+ cable aside.
    10.  
    11. Loosen the 2 clamps and remove the turbo-to-air cooler pipe.
    12.  
    13. Disconnect the alternator electrical connectors.
    14.  
    15. Remove the bolts and the alternator.
    16.  
    17. To install, reverse the removal procedure. Torque the mounting bolts to 35 ft. lbs. (47 Nm).
    18.  

    Single Alternator
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Disconnect the batteries.
    4.  
    5. Remove the cooling fan.
    6.  
    7. Rotate the accessory drive belt tensioner clockwise and remove the drive belt from the alternator pulley.
    8.  
    9. Disconnect the alternator electrical connectors.
    10.  
    11. Remove the bolts and the alternator.
    12.  
    13. To install, reverse the removal procedure. Torque the mounting bolts to 35 ft. lbs. (47 Nm).

      Click image to see an enlarged view

      Fig. Single alternator mounting-6.0L w/single alternator; 7.3L similar

    14.  

    6.8L Engines
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Air cleaner assembly
       
      Mass Air Flow (MAF) sensor electrical connector
       
      Accessory drive belt
       
      Alternator electrical connectors
       
      Bolts retaining the upper intake plenum to the alternator bracket
       
      Alternator bolts and the alternator
       

    4.  

    To install:

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Installation is the reverse of removal, please note the following torques:
      1. Bolts retaining the upper intake plenum to the alternator bracket. Tighten to 80-106 inch lbs. (7-9 Nm).
      2.  
      3. Alternator bolts and the alternator. Tighten to 16-21 ft. lbs. (22-28 Nm).
      4.  

    4.  

    7.3L Engine
    Dual Alternator
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Single (upper) alternator
       
      Electrical harness connectors at the alternator assembly
       
      Alternator bolts and the alternator from the vehicle
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator in position
       
      Alternator retaining bolts and tighten to 35 ft. lbs. (47 Nm).
       
      Single (upper) alternator
       

    2.  

    Single Alternator
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Air cleaner, if necessary
       
      Drive belt from the alternator pulley
       
      Electrical harness connectors at the alternator assembly
       
      Alternator bolts and the alternator from the vehicle
       

    4.  

    To install:

    1. Install or connect the following:

      Alternator in position
       
      Alternator retaining bolts and tighten to 35 ft. lbs. (47 Nm).
       

    2.  
    3. Install all remaining components in the reverse order of removal.
    4.  

    Lightning Models
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Bolt retaining the degas bottle (coolant reservoir) and position the bottle aside
       
      Supercharger drive belt
       
      Accessory drive belt
       
      Upper alternator bracket
       
      Lower alternator brackets
       
      Upper bracket bolts
       
      Electrical connector from the alternator bracket
       
      Right hand lower bolt
       
      Alternator bracket
       
      Alternator electrical connectors
       
      Alternator
       

    4.  

    To install:

    Click image to see an enlarged view

    Fig. Alternator mounting bracket installation-Lightning

    1. Installation is the reverse of removal, please note the following torques:
      1. All alternator bracket bolts to 89 inch lbs. (10 Nm).
      2.  
      3. Right hand lower bolt to 18 ft. lbs. (25 Nm).
      4.  

    2.  

     
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