Ok I am doing the g2 to g3 alternator swap on my 92 f350 with 351w. here's the issue I got a alternator from the junkyard out of a 90 something mustang v6 that fit in just fine. think it was a 94 or 95. got it all in and wired up and low and behold it's not charging. I should have had it tested before I put it in. I think it's bad.

here's my real question I have a newish (its about 2 years old but only got about 100 miles on it before it blew a head gasket) alternator out of a 98 windstar with 3.8 in it. It will not bolt up not even close. Can I change the housings? if so how? They look the same just mount different. I would like to put the housing off the mustang alternator on the new one I have for the windstar. I just don't have the extra $ for a new alternator and this was the only one in the junkyard close by that I could find.

By looking at pictures of the 2 it looks like maybe I could just change the front housing piece to change the way it mounts?

 

Why not troubleshoot the one that you have? You can full-field the alternator (bypasses the regulator and applies 12V across the field winding) to see if the regulator is bad (check online - plenty of info on how to do it).

The regulator and brushes are serviceable from the outside - it makes it very easy to work on these alternators.

 

good call I will check it out here in a bit. Just figured it would be cheaper to strip that other one. regulator is $39.00 and man I am broke these days lol

 

Yes you can swap the internals between cases.

 

Well I got it figured out. the 3.8l windstar alt. that was only a couple years old's bearings were froze up so I used the lifetime warranty and then exchanged it for the 3.0l windstar version lol. Works like a charm. there is a big difference between the stock 70 amp alt and the 130 amp one. lights do not dim at idle and gauge doesn't move at idle or any rpm change. Now I can add some off road lights! I recommend this to anyone that has the g2 alt. easy swap and WELL worth it. I used the wiring out of the old dead windstar and added a fuse. It had some good thick wire running from the alt. and its originally 130 amp so figured it would be the best wire to use rather than heavy 1 gauge or so car audio wire.

 

Glad to hear it, and I have the exact same parts (Windstar fuse/relay block with the big alternator fuse on the end) that I plan on eventually putting into my truck as well (am going to swap out the stupid keyed power and fuel pump relays on my 1990 with standard plug-in ones on the Windstar relay block).

 

That's my plan also. I am using the hole fuse box from under the hood of the windstar. Gonna use the extra relays and fuses for accessories (winch, lights, stereo and what not I am also thinking about going to electric fans.. Mounted the box over were the jack use to be under the hood. I will get some pics once I got it all buttoned up.