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Who has changed their Alternator on a Zetec. Any tips or tricks to share? I am doing the switch this weekend and looking for some input. I have bought a replacement battery cable set from Ford to put in at the same time. The original cables are all cracked and corroded.

(04-01-2011, 08:50 AM)Focus man. Focus. Wrote: [ -> ]Who has changed their Alternator on a Zetec. Any tips or tricks to share? I am doing the switch this weekend and looking for some input. I have bought a replacement battery cable set from Ford to put in at the same time. The original cables are all cracked and corroded.

My first inclination is to say "pay a pro to do it" - but I know that's not in your DNA.

From what I observed LOL it's a beotch ... get the car as high off the ground as you can ... and may I also suggest that you spend the money and get the highest amp version available ... IIRC 130 amps vs. 110.

THis might also be a good time to replace the serpentine of you think it might be in need.

I pulled mine out through the top. I followed the instructions in the Haynes manual.

1. move coolant overflow and PS reservoir out of the way.
2. bend PS reservoir bracket 'tab' down, out of the way.
3. have a beer.
4. remove serpentine belt.
5. remove or loosen bolts. You won't be able to remove one bold until the whole alternator is moved.
6. undo electrical connections on alternator (old grounding post may snap off).
7. undo bolts holding stuff to firewall, intake, head, etc.
8. have another beer.
9. turn the alternator pulley side up in the little bit of cavity you've made.
10. swear at Ford for such a stupid design.
11. try to pull the alternator out, while wiggling it, turning it, swearing, throwing tools, etc... It will eventually come out.
12. have another beer.
13. maneuver new alternator into place, reverse of removal. Swearing, throwing tools, turning and wiggling all involved. More beer too.

It's a frigging picnic, and a good time will be had by all. As long as there is enough beer, bandaids, and tools to throw. It took me a total of 4 hours. Once I got it done, I realized that if I could rock the engine forward about 1 inch, it would be alot easier. Maybe undo the rear motor mount (dog bone), and jack up on it, to 'roll' the engine forward.

I read the Haynes manual. You added a couple steps. LOL

(04-02-2011, 10:13 AM)Focus man. Focus. Wrote: [ -> ]I read the Haynes manual. You added a couple steps. LOL

He did ... but I wouldn't remove them if I were you.

I didn't plan on it.

I remember changing the alternator on my dad's old '87 Escort with the 1.9l in it. I think I changed the alternator in 20 minutes flat. Same for my old '84 Mustang Gt. Three bolts, two wires, done. Then this thing... My wife steered clear of me while I was working on it. You think doing drum brakes is bad...

I know the good old days. Small block chev. 2 bolts, a plug and a wire. Done

I'm not looking forward to this. But ya gotta do what ya gotta do. Right?

I've replaced the alternator once. Technically, twice if you count the re-install after the Powerworks went on.
If you loosen the passenger side motor mount from the chassis you can leverage the motor around to gain clearance.