This weekend my alternator decided to crap out, I have the factory Ford service manual and printed off their 22 pages worth of steps to trouble shoot where a failure could have happened, as in wiring, engine computer, alternator, ect..... and confirmed it was in fact the alternator was toast. I am lucky to live in Billings MT where I am blessed with regional parts warehouse for 4 major part house (Napa, Car Quest, O-Riely and Auto Zone) so in the past if the local store did not have it the warehouse did and you could simply head over and pick the item up there. No one, not even Ford stocks a 200 amp alternator in Billings. Local rebuild shop has never touched one, could rebuild it but has no parts and would have to order.

Luckily this is not my daily driver and I found a local salvage yard had one for 60 bucks but not open until today. I removed old alternator Saturday and waited.

Got it installed and will order parts to rebuild the removed alternator and will now have a spare.

Really wasn't that bad of a job, other than almost zero temperature and having to work outside. Inner fender needs to come off, then there is good access to unplug the wires and remove three mounting bolts. I did make a special tool to remove tension from belt. For those who want to copy it, 1 inch flat iron, 3/8 inch key stock. Long side is 21.5 inches, short side is 7.5 inches and I drilled a half inch hole in center of flat iron for key stock to fit in and basically plug welded one side and the sides on the other. Works out really slick compared to ratchet and cheaper pipe. I made it with out any measurements from pickup so if I had to do it over I would trim 1 inch off the short side, but it does barely clear fan hub as is.

I have a belt tension tool, but the 3/8 key is wrong angle and my extension piece that would make tool look like one I made has a 1/2 drive instead of 3/8 so I made one for less than a few bucks and 20 minutes of my time and some welding rod.

Pictures below for those interested.

Jeff

Picture of failed alternator once inner fender was removed.



Alternator removed





Ratchet and jack handle to remove belt tension. Who ever designed this radiator shroud has clearly never worked on a car/pickup as it sucks major _______.




Picture of my tool in place of ratchet once I had re-installed the belt. I might have to take another picture once I paint the tool red so that it is easier to see. I paint all special tools I make red so they stand out, verses just scrap iron.




Pictures of belt tension tool



I used a grinder to bevel off the edges slightly to make it easier to slip the tool in to square head on tensioner.

 

At least yours didn't carch on Fire like mine did.

 

Nice special tool, thanks for the write and good post title, should come on a search quickly.