Genuine Mercury Cougar Voltage Regulator

Mercury Cougar Voltage Regulator Parts Questions & Answers

• Regulator Assembly - Voltage
  FOPZ-10316-A
  Q: How do you replace the Voltage Regulator on Mercury Cougar?

  A: 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.