Disassembling a Motorcraft alternator is a fairly simple job that can be done in about a half hour. The Motorcraft alternator design is very similar to most other alternator brands, and is fastened together with four bolts. The alternator has three main parts, which are the two end caps and a stator, and some interior parts that should be removed when disassembling the device. You can take the alternator apart with a few shop tools.
Draw a line across both halves of the alternator housing with a black marker so you can line up the parts easier when you go to put the alternator together. Unfasten the four bolts on the side of the housing that holds the alternator together with a socket wrench.
Tap the side of the alternator with a rubber mallet to loosen the parts, and pull the front half off the alternator motor. The front half is the side with the pulley.
Detach the two brush springs from the back half of the alternator with a screwdriver, and loosen the three bolts that hold the stator on the alternator with a socket wrench. Remove the stator from the alternator.
Loosen the bolts that secure the regulator and brush assembly to the alternator with a socket wrench and slide the main post off the bridge. Remove the pulley from the front half of the alternator by loosening the bolt on the pulley with an Allen wrench and sliding the pulley off the shaft.
