Well since I have access to a free 3G alternator from a 3.0 liter taurus I am planning a swap from my current 2G alternator to a 3G just for peace of mind. I am curious as to how one clocks the 3G to make it fit your application. It appears that I can loosen three small hex bolts and then what? Do I have to do any weird tricks like removing brushes like on some AC-Delco alternators?

 

IIRC, you can slide it apart without any resistance, but to put it back together you need to install the brushes and hold them down. This is accomplished by inserting a paper clip or the like throught the small hole across the brush face. Then when the alternator casing is back together in the desired configuration pull the clips and voila, functioning alternator.

 

i just did this on mine. i used this website as a guide (i did a full rebuild, bearings, slip ring, voltage reg/brush assy. How to rebuild a Ford alternator | Alternator Rebuild Kits

-remove voltage reg/brush assy
-remove charge cable nut
-remove three long thin bolts
-the back half of the case comes off. if it doesn't, tapping it on the side with a rubber mallet did the trick for me. this will expose the rectifier.
-clamp one of the ears in your bench vise, rectifier side down.
-with your hand at the ready to catch the stator/winding assembly, tap all around the side of the case with your rubber mallet. upgrade to a ball peen if need be.
-if that doesn't work, i've read that applying even heat to the case also helps. DO NOT pull on the rectifier, you could damage the soldered connections.
-clock it.
-assembly is pretty much reverse of dissassembly. just make sure you slide everything back straight, tapping on the case helps. you can sand the ground path where the rectifier fits into the front half of the case. like muldo said, using a paper clip will make it easier to install the voltage reg/brush assembly.

good luck!