I have been needing to change a couple of regulators on some generation 4 alternators. I had a buddy that used to rebuild alts and starters for a living. I watched him do several and I don't think it is very difficult. So here are a few videos that show the "how to":

 

This is a pretty neat test procedure!:

 

Here is a 3G overhaul:

 

Great post!!

 

Rep's sent!

 

Thanks guys!!

We need to find some places that sell the parts fairly cheap and make a list of them on this thread. Feel free to post ay parts supplier on here that we could purchase components from.

 

Here is a parts link:
Alternator Parts - Starter Parts - Alternator & Starter Rebuild kits - REPAIR KIT-FD 4G

 

This one has a lot of 3G parts:
Ford Alternator upgrade & repair kits, Quick Start Rebuild Kits

 

Regulators, bearings, brushes, rectifiers, and pulley's here.

RJM Injection Tech — Alternator Accessories

 

Good job, Bruno. My only caution to people rebuilding their own is to use high quality parts. I once put a new bearing in an alternator from a lawn mower repair shop. It didn't last long and when it failed it destroyed the alternator which also took out the regulator. I learned the hard way that alternators require a special high-temp bearing.

 

I will say that all of this information is great to have, especially if you have the tools, skills, and use high quality parts as Gary mentioned. However, I will also say that sometimes it is best to have a local repair shop take care of it for you. Sometimes the extra $10-20 spent on having someone else do the rebuild is worth it, especially if your time is at a premium and your shop will give you a warranty, as most reputable ones will.

The last time I needed an alternator, I called my local shop up and they had it ready in 3 hours and only charged me $35; they even trusted me to bring the core back after I had it in my hands. (Normally I would have them rebuild the factory unit, but in this case the factory unit was in Stillwater on my old '83 and I was in Moore - 70 miles apart.)

 

Steps to rebuilding a Ford alternator generator for your F-series truck:

Step 1) Get in your vehicle.

Step 2) Drive to the nearest automotive parts store.

Step 3) Remove the old alternator and take it inside.

Step 4) Get new alternator.

Step 5) Bolt it in and drive away.

 

^ That's one way to do it! LOL!

 

A rebuilt Hitachi alternator for my wife's Honda (Isuzu) is ~$250 and $100 core.
The toasted regulator inside is $28 outright, and it takes <10 minutes to open the case and replace it.

Sure, I COULD just swap it out -trusting someone else to do it right- , I COULD rebuild the entire thing -brushes, rectifier, bearings too- , or I could do the cheap, quick an dirty repair to a vehicle with over 220k on the clock and be on the road in less than an hour.

 

I guess the rebuilders in OKC are a lot more reasonable than the ones in Tulsa. In Tulsa there is no price difference between a rebuild shop and O'Reilly's. I always check before I buy one.