The following covers the procedure to replace a non-integral type voltage regulator in Ford Explorer models from 1991 through 1995 only. Explorer models newer than 1995 have integral voltage regulators. If an integral voltage regulator isn't working properly, the owner has to replace the entire alternator.
Disconnect the negative battery cable from the battery. Use a Torx screwdriver to remove the four retaining screws that hold the regulator onto the rear housing of the alternator. Remove the regulator, with the brush and terminal holder still attached.
Pry off the cap that covers the A terminal screw head with a small pry bar or flathead screwdriver. Set the cap aside in a safe place. Remove the two Torx screws that hold the regulator to the brush holder. Separate the two.
Reinstall the brush holder onto the new regulator the two retaining screws. Tighten the screws to 25 to 35 inch pounds with a torque wrench. Replace the cap on the head of the A terminal screw.
Press the brushes into the brush holder. Hold the brushes in position by inserting a paper clip through the location hole in the regulator and the holes in the brushes. Reinstall the regulator and brush holder assembly. Remove the paper clip.
Reinstall the retaining screws and tighten them to 20 to 30 inch pounds. Reconnect the negative battery cable.
