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Replacing the alternator on a Zetec.
#1
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.
Focus man, Focus........ Team Psychological Disaster
2008 Taurus X to be modded.
2002 ZX5 parted out. Forever known as the "SLOCUS".

2010 Dyno #'s 102.96HP/105.84TQ
2011 Dyno #'s 111.44HP/115.17TQ
Still The Weakest LinkBlush

Dial 1-800-AUTO-PARTS for your local speed shop.
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#2
(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.
2008 Fusion SEL MTX - DD1 * 2009 Fusion SEL - DD2 * 2007 Focus ZXW - R*I*P * 2004 Focus ZTW CD Silver - sold * 2004 Focus ZTW Black - sold * 2003 Focus ZTW Black - sold * 2001 Focus ZTW Gold - sold * 2000 Focus SE Wagon (ZTW option) - Black - sold * 2000 Focus SE Wagon (ZTW option) - Gold R*I*P

2003 Focus ZX5 infra-red Track Rat - R*I*P
2003 ZX5 CD Silver Track Rat - retired, but still in the driveway


New track rat: 2000 ZX3, Atlantic Blue * JRSC with lots more to come

* New Zetec crate motor - NFG - thanks Topspeed *
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#3
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. Smile 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.
Ryan and the Silver Sedan
++++++++++++++++++++++++
2008 Mazda5 GS/Copper Red Mica/2.3 MZR 5AT/22% Tint
[Image: 49951.png]
2011 Ford F150 FX4 Supercrew/Race Red/3.5 TT EcoBoost
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#4
I read the Haynes manual. You added a couple steps. LOL
Focus man, Focus........ Team Psychological Disaster
2008 Taurus X to be modded.
2002 ZX5 parted out. Forever known as the "SLOCUS".

2010 Dyno #'s 102.96HP/105.84TQ
2011 Dyno #'s 111.44HP/115.17TQ
Still The Weakest LinkBlush

Dial 1-800-AUTO-PARTS for your local speed shop.
Reply
#5
(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.
2008 Fusion SEL MTX - DD1 * 2009 Fusion SEL - DD2 * 2007 Focus ZXW - R*I*P * 2004 Focus ZTW CD Silver - sold * 2004 Focus ZTW Black - sold * 2003 Focus ZTW Black - sold * 2001 Focus ZTW Gold - sold * 2000 Focus SE Wagon (ZTW option) - Black - sold * 2000 Focus SE Wagon (ZTW option) - Gold R*I*P

2003 Focus ZX5 infra-red Track Rat - R*I*P
2003 ZX5 CD Silver Track Rat - retired, but still in the driveway


New track rat: 2000 ZX3, Atlantic Blue * JRSC with lots more to come

* New Zetec crate motor - NFG - thanks Topspeed *
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#6
I didn't plan on it.
Focus man, Focus........ Team Psychological Disaster
2008 Taurus X to be modded.
2002 ZX5 parted out. Forever known as the "SLOCUS".

2010 Dyno #'s 102.96HP/105.84TQ
2011 Dyno #'s 111.44HP/115.17TQ
Still The Weakest LinkBlush

Dial 1-800-AUTO-PARTS for your local speed shop.
Reply
#7
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... Angry My wife steered clear of me while I was working on it. You think doing drum brakes is bad... Smile
Ryan and the Silver Sedan
++++++++++++++++++++++++
2008 Mazda5 GS/Copper Red Mica/2.3 MZR 5AT/22% Tint
[Image: 49951.png]
2011 Ford F150 FX4 Supercrew/Race Red/3.5 TT EcoBoost
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#8
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?
Focus man, Focus........ Team Psychological Disaster
2008 Taurus X to be modded.
2002 ZX5 parted out. Forever known as the "SLOCUS".

2010 Dyno #'s 102.96HP/105.84TQ
2011 Dyno #'s 111.44HP/115.17TQ
Still The Weakest LinkBlush

Dial 1-800-AUTO-PARTS for your local speed shop.
Reply
#9
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.
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