I've had two alternators replaced under warranty. And the replacements are always 'Remanufactured' units, not new. So, I decided to buy a new, larger capacity alternator. This unit is supposed to have higher output at lower rpm's and higher output during normal driving.
Here is the alternator I bought (140A HD unit):
http://www.alternatorparts.com/6g-serie ... nator.html
Let me tell you, I feel sorry for the guys who work on these things for a living. What a PITA!
To get to the alternator, you must disconnect the batteries, then you have to move the MAP sensor, Power Steering reservoir, main harness bundle only to discover a couple of other things that complicate moving the harness. First is something SMB added - I don't know what it is - and the other looks to be a vaccuum distribution piece for the 4wd. Then you can see the brace for the intercooler to turbo hose, take it out. Now you can remove the intercooler to turbo hose - if you can get it loose. The clamp on the back of the hose is buried behind the alternator and I could get a socket on it and turn it about 1/6 of a turn - and it takes about 20 turns to get it loose enough! Take the front clamp off and remove the hose completely.
Now for the alternator. Move the transmission dipstick tube and 4 bolts and jump when the belt tensioner pulls the alternator -wham.... Ok, so far so good.
Ideally, you can rotate the tensioner (as the books says to do) and lock it in position and the belt is no problem. First step to rotate the tensioner calls for removing the radiator. So, I look for alternates.
I finally decided I could hook the alternater under the belt and use a long prybar to get it up into position. That actually worked!! Reassemble all the above, button it up.
All went well until I started it up. No charge! %#@* and more. The belt came off. Probably when the alternator jumped, the belt came mostly off one or more pulleys. Take it all apart and repeat the above. This time carefully examine the belt and ensure it is properly on all the pulleys, most of which can only be seen from below. Reassemble and fire it up. All is fine now.
Anybody want a Ford Remanufactured Alternator with only 100 miles on it? It's a lot cheaper than buying it from Ford.