I am getting my alternator re-built & I just removed it, couple of questions:

1. the larger single wire that attaches at the back of the alternator had a rubber boot on it (felt like plastic though), in the process of attempting to pull it back, it disentigrated.....but exposed the nut that has to be removed to remove this wiring connection. Does it create a un-safe situation to not have this boot on covering this connection ?

2. the other electrical connection is a plastic "clip-on" connection that has two 20ga +/- wires into the back of it, it clips onto a grey plastic mounting point attached to the alternator. Part of the grey mounting point that holds the 2 together broke. Replace ?

first alternator replacement on a 2002 F250 crew 4x4 7.3L, 167,000 miles

thanks for your opinions

p.s. that tension pulley on the belt ain't easy !!!! granted I don't have a proper bar & did it w/ 1/2" socket, but it just wasn't simple

 

It's not really any more unsafe than having exposed red leads on your batteries, if you've replaced the terminals like I have. Just don't forget it's open and lean on the alternator there with sweaty hands while working on something on the back of the motor...

The clip can be tie-wrapped down if you get creative with how you route it. I had to do the same thing.

You can use a large box wrench (closed in 12pt side) for extra torque on the socket wrench, if you have one big enough. I use an 18mm...

 

Just replaced my alternator last week- Same thing happened to me on the twin molex plug. I took some silicone caulk (just a little bit on the end of a small screwdriver) & dabbed it in where the plastic piece broke out.- Let it set for a couple hours and your good to go - Like Izzy said the other one is'nt a big deal.

 

You can probably find a replacement at Napa, or this guy's got one; and a bunch of other neat stuff too:
RJM Injection Tech Battery Cable Parts