My alternator went out on me today. Looks like the regulator went bad, things are smoked on it.

I can't beleive that some idiot would design and a company would actually produce a product so poorly thought out! First off, who puts an alternator (a very vital and important electrical component mind you) down right next to the wheel well; where rain, snow, salt, liquid de-icer, etc, can get to it!!?!?
To continue off that, you can barely get to it to get it disassembled from the mounts since it's below the battery, IC pipe, wiring harnesses. Next to find out that there's no room for it to come out. So I called the local Ford dealer to price a new one and see if there was a trick to getting it out. A new one is $628!!! and that's with me giving them my core!! Then the service guy got into what it takes to get it out, basically disassembling most everything on the left side of the engine. I ended up pulling the battery, battery box, intake box, cut loose all the wiring harnesses from the keepers, and can only move the IC pipe out of the way since they designed that so poorly as well.

I'm just pissed cuz it takes so much work for a silly alternator. Makes me want my '99 7.3L back!!! 3 bolts, pull the wires and belt off it and it comes right off!

Rant over.

 

I hope you put a new one on and not a re manufactured unit... Never had one go out on my 6.4l but on the 7.3 comp truck it went out and they replaced it with a reman and that went out 2 weeks later i told them to put a new one and now 4 years later still running good.

 

So it's almost a cab off for an alternator,,LOL $628 bucks is totally ridiculous. You had the high output one I'm guessing.

 

Does not surprise me one bit

 

no..not so bad...take the upper shroud off.

 

Dealer was telling me to pull the fan shroud and fan, and to do that you hafta move/pull the radiator. Kinda beyond acceptable for "normal" repairs.

 

OR you could remove the right hand fender splash shield and remove and install the alternator in about 30 minutes like the Ford Work Shop Manual says.

Disconnect the batteries. For additional information, refer to Section 414-01.
Remove the air cleaner assembly. For additional information, refer to Section 303-12.
Remove the fender splash shield. For additional information, refer to Section 501-02.
Rotate the accessory drive belt tensioner clockwise and remove the drive belt from the generator pulley.
Remove the nut and position the generator B+ terminal aside.
To install, tighten to 12 Nm (9 lb-ft).
Disconnect the generator electrical connector.
Remove the 2 lower bolts to the generator.
To install, tighten to 47 Nm (35 lb-ft).
Remove the upper bolt and the generator.
To install, tighten to 47 Nm (35 lb-ft).
To install, reverse the removal procedure.

 

I don't carry a Ford Workshop Manual, that's why I called the dealer. He proceeded to tell me I needed to pull the fan, shroud and radiator, about a 1.5-2 hr job. Thanks for the specs.

I got it out and changed. Bought a used one from a local junkyard for $160, no core, w/6 month warranty. Figured for those dollars I can tear back into the truck again now that I know how.

In the meantime, I'm tearing apart my whole intake assembly and will probably be doing some 'needed' upgrades: EGR delete, new passenger IC pipe, CCV mod. Everything was crap full of oil. Pulled the CAC and when I pulled the bottom boot it drained oil for a little while.

 

Disconnected batteries, Removed right front tire, Pulled right fender splash sheild, removed belt, removed bolts, removed wires, pulled generator out, 2 hours,
ordered new one today same make that came in truck
(200 amp foreign made) I will post part # & make
(P.A.S.C.O. $436.87 no core charge) they are changing pully from old to new, I will put back in tomorrow

 

saw your post when it started and then stumbled on an alt.on e-bay, said it was for a 6.4 and was priced below 200 "buy it now" not a bid .dont remember the amperage? for that kind of $[465] should at least get a kiss!

 

Replaced with new, 2 hours, hardest part was getting belt back on!

 

Cost new replacement, not rebuilt came with new pully

 

Hey just smoked alt on my 08 f350 6.4 been dreading changing it all day ! Thanks a ton for the info , sounds like it wont be as bad as I thought , Thanks again Dirtmotor

 

Big truck alternators get really really pricey, I think it has more to do with duty cycle, than amps on the tag.

 

so far so good , inner fender off alternator off , next up order new one from ford price was less than I thought . Toughest part so far was getting to belt tensioner . Finally got break over bar in and used a punch through hole in bar and pried off frame . Not great but it worked .