Good Morning Primitive,
I just replaced my alternator over the holidays so it's pretty fresh. So fresh in fact that all the tools necessary are still sitting on the work bench if you just want to park in the driveway and have at it
. Not sure how many times you have dug into the 6.0 engine bay but my number one recommendation is be patient and don't get frustrated if it takes a lot longer than you planned. Remember working on a 6.0 in an E-Series is just like in a Pick-Up only in a bottle, a tight fitting bottle.
Forum member Geofff has the Ford shop manuals for the 2004 years available for download on his blog site. He posted the links in another thread and stated it was OK to use. Heads up, it is my experience the procedures in the Ford manual make each job sound a lot easier than in reality. I find I often need to remove more "stuff" that is in the way than the manual says I need to. By far the most frustrating job on my 6.0 to do is loosen the belt tentioner for removal and reinstall of the belt. For this reason alone I probably remove more than most just to have good access to it.
Sportsmobile & Ford E-Series Van Manuals
Look/download the link "Workshop Manual" on page 414-02-1 you will find the alternator replacement info for the 6.0.
- Eric