Ford Freestar, Monterey 2004-2006

Alternator

Print

Diagnosis & Testing



On-Vehicle Tests

WARNING
To prevent damage to the generator, do not make jumper wire connections except as directed.


WARNING
Do not allow any metal object to come in contact with the housing and the internal diode cooling fins with the ignition switch in the ON or OFF positions. A short circuit may result and burn out the diodes.


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


NOTE
Refer to the battery tester manual for complete directions for testing the charging system.

  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.  

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 generator B+ output terminal, circuit 2037 (RD).
  6.  
  7. With the engine running at approximately 2,000 rpm, adjust the tester load bank to determine the output of the generator. Generator output should be greater than the graph shown.

    Click image to see an enlarged view

    Fig. Alternator load test graph

  8.  

No Load Test
  1. Switch the tester to the voltmeter function.
  2.  
  3. Connect the voltmeter positive lead to the generator B+ terminal, circuit 2037 (RD) and the negative lead to ground.
  4.  
  5. Turn all electrical accessories off.
  6.  
  7. With the engine running at approximately 2,000 rpm, check the generator output voltage. The voltage should be between 13.0 and 15.0 volts.
  8.  

Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the accessory drive belt.
  4.  
  5. Detach the alternator wiring connector.
  6.  
  7. Remove the positive cable nut.
  8.  
  9. Remove the alternator.

    Click image to see an enlarged view

    Fig. Alternator mounting-3.9L engine, 4.2L similar

  10.  

To install:

  1. Position the alternator on the engine.
  2.  
  3. Install the alternator mounting bolts. Tighten the bolts to 18 ft. lbs. (25 Nm) on 2004-05 models, or 35 ft. lbs. (47 Nm) on 2006 models.
  4.  
  5. Tighten the positive cable nut to 71 INCH lbs. (8 Nm).
  6.  
  7. Connect the wiring connector.
  8.  
  9. Install and tension the accessory drive belt.
  10.  
  11. Connect the negative battery cable.
  12.  

 
label.common.footer.alt.autozoneLogo