Ford FOPZ-10316-A Regulator Assembly - Voltage

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Remove the battery or air cleaner duct.

Carefully remove both brushes, being careful not to lose the springs.

To remove the alternator, set it on a clean workbench. Then, remove the four voltage regulator mounting screws to detach the voltage regulator/brush holder assembly. Lift the assembly from the alternator and detach the rubber plugs. Remove the brush lead retaining screws and nuts to separate the brush leads from the holder. Note that the screws have Torx heads and require a special screwdriver. After noting the relationship of the brushes to the brush holder assembly, remove both brushes, being careful not to lose the springs. If installing a new voltage regulator, insert the old brushes into the brush holder of the new regulator. If installing new brushes, insert them into the brush holder of the old regulator, ensuring the springs are properly compressed and the brushes are properly inserted into the recesses in the brush holder. Install the brush lead retaining screws and nuts. Insert a short section of wire, like a paper clip, through the hole in the voltage regulator to hold the brushes in the retracted position during regulator installation. Carefully install the regulator, making sure the brushes don't hang up on the rotor. Install the voltage regulator screws and tighten them securely. Finally, remove the wire or paper clip and install the alternator.

To remove the alternator, set it on a clean workbench and detach the voltage regulator by removing the four mounting screws. Then, remove the plastic cover over one of the brush retaining screws and separate the brush leads from the holder by removing the screws and nuts. Take note of the brush relationship and remove both brushes, being careful not to lose the springs. If installing a new voltage regulator, insert the old brushes into the brush holder of the new regulator, or insert new brushes into the brush holder of the old regulator. Install the brush lead retaining screws and nuts, and cover the head of the "A" terminal screw with electrical tape. Use a thin wire, like a paper clip, to hold the brushes in the retracted position during regulator installation. Carefully install the regulator, ensuring the brushes don't hang on the rotor and the brush leads are looped toward the brush end of the holder. Tighten the regulator screws securely and remove the paper clip. For an internal fan type alternator, remove the four through bolts retaining the case together. Heat the bearing portion of the rear case with a soldering iron and then insert a flat-bladed screwdriver between the stator core and mounting flange to remove the rear cover. Use a soldering iron to remove solder from the rectifier and stator lead, and unsolder the regulator/brush holder assembly from the rectifier. Remove the solder from the brush pigtails. To install, reverse the removal procedure, making sure to push the brushes into the holder and use a paper clip to retain them in the retracted position when installing the rear cover. Heat the rear case bearing area before installing the rear case and remove the paper clip after installation.

To detach the cable from the negative terminal of the battery, locate the voltage regulator on the right side of the engine compartment. If necessary, remove the battery or air cleaner duct to gain access to the voltage regulator. Unplug the electrical connector from the voltage regulator and remove the regulator mounting bolts. Finally, remove the regulator and install it in reverse order.