1991 1999 ford explorer chilton User Manual

							Unbolt the battery (B+) lead from the back of the alternator ...
Label and disengage all of the wiring connectors from the alternator. To disconnect push-on type
terminals, disengage the lock tab and pull straight off.
3. 
Remove the alternator bolts, then remove the alternator from the engine
4. 
... then remove the alternator mounting bolts
Remove the alternator from its mounting bracket
To install: HOW TO USE THIS BOOK
222 REMOVAL & INSTALLATION 
						

							Position the alternator on the engine.
5. 
Install the alternator mounting bolts. On 3.8L and 5.0L engines, tighten the upper bolt to 16-21 ft. lbs.
(21-29 Nm) and the lower bolt to 30-40 ft. lbs. (40-55 Nm). On 4.6L engines, tighten both bolts to
15-22 ft. lbs. (20-30 Nm).
6. 
On 4.6L engines, install the alternator mounting bracket and bolts. Tighten the bolts to 71-106 inch
lbs. (8-12 Nm).
7. 
Install the accessory drive belt. Ensure that the drive belt is properly installed on the pulleys before
starting the engine.
8. 
Attach all engine wiring harness connectors to the alternator.
9. 
Connect the negative battery cable.
10. 
Voltage Regulator
REMOVAL & INSTALLATION
1991-95 models with non-integral type regulator
The regulator is attached to the alternator by 4 Torx® head screws Click to enlarge
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Voltage Regulator 223 
						

							Disconnect the negative battery cable.
1. 
Remove 4 Torx® head screws holding the voltage regulator to the alternator rear housing. Remove
the regulator, with the brush and terminal holder attached.
2. 
Hold the regulator in one hand and pry off the cap covering the Aterminal screw head with a small
prybar.
3. 
Holding the regulator in one hand, break off the tab covering the A screw to expose the brush holder retaining screws
Click to enlarge
Remove 2 Torx® head screws retaining the regulator to the brush holder. Separate the regulator from
the brush holder.
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224 REMOVAL & INSTALLATION 
						

							
To install:
Install the brush holder on the regulator with 2 retaining screws. Tighten the screws to 25-35 inch lbs.
(2.8-4.0 Nm).
5. 
Exploded view of the voltage regulator and brush holder assembly Click to enlarge
Install the cap on the head of the Aterminal screw.
6. 
Depress the brushes into the holder and hold the brushes in position by inserting a standard size paper
clip, or equivalent tool, through both the location hole in the regulator and through the holes in the
brushes.
7. 
Install the regulator/brush holder assembly and remove the paper clip. Install the attaching screws and
tighten to 20-30 inch lbs. (2.3-3.4 Nm).
8. 
Connect the negative battery cable.
9. 
1995-99 models with integral type regulator
The internal voltage regulator used on alternators used with these vehicles is not removable or, in any other
way, serviceable. If the voltage regulator is found to be defective, a new alternator must be installed. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 225 
						

							Example of the integral type regulator atlernator
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
226 REMOVAL & INSTALLATION 
						

							
STARTING SYSTEM
General Information
The starting system is designed to rotate the engine at a speed fast enough for the engine to start. The starting
system is comprised of the following components:
Permanent magnet gear-reduction starter motor with a solenoid-actuated drive
· 
Battery
· 
Remote control starter switch (part of the ignition switch)
· 
Park/Neutral Position (PNP) or Manual Lever Position (MLP) switch (on 1994 automatic
transmission models) or Transmission Range (TR) sensor (on 1995-99 automatic transmission
models)
· 
Clutch Pedal Position (CPP) switch (on manual transmission models)
· 
Starter relay
· 
Heavy circuit wiring
· 
Exploded view of the coil type starterClick to enlarge
STARTING SYSTEM 227 
						

							Exploded view of the permanent magnet type starter
Click to enlarge
Heavy cables, connectors and switches are utilized by the starting system because of the large amount of
amperage this system is required to handle while cranking the engine. For premium starter motor function, the
resistance in the starting system must be kept to an absolute minimum.
A discharged or faulty battery, loose or corroded connections, or partially broken cables will result in
slower-than-normal cranking speeds. The amount of damage evident may even prevent the starter motor
from rotating the engine at all.
Vehicles equipped with a manual transmission are equipped with a Clutch Pedal Position (CPP) switch in the
starter circuit, which is designed to prevent the starter motor from operating unless the clutch pedal is
depressed. Vehicles equipped with automatic transmissions are equipped with either a Park/Neutral Position
(PNP) switch, a Manual Lever Position (MLP) switch or a Transmission Range (TR) sensor in the starter
circuit. These switches prevent the starter motor from functioning unless the transmission range selector lever
is in Neutral (N) or Park (P). HOW TO USE THIS BOOK
228 General Information 
						

							
The starter motor is a 12 volt assembly, which has the starter solenoid mounted on the drive end-housing. The
starter solenoid energizes when the relay contacts are closed. When the solenoid energizes, the starter drive
engages with the flywheel ring gear, rotating the crankshaft and starting the engine. An overrunning clutch in
the starter drive assembly protects the starter motor from excessive speed when the engine starts.
Starter
TESTING
Use the charts to help locate and diagnose starting system problems. Remember that the starter uses large
amounts of current during operation, so use all appropriate precautions during testing.
Starter system inspection chartClick to enlarge
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Starter 229 
						

							Starter system evaluation procedure chart
Click to enlarge
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Raise the front of the vehicle and install jackstands beneath the frame. Firmly apply the parking brake
and place blocks in back of the rear wheels.
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230 TESTING 
						

							Disconnect all wires connected to the starter, including this ground wire on the starter moutnting
bolt stud
Tag and disconnect the wiring at the starter.
3. 
WARNING
When detaching the hardshell connector at the S-terminal, grasp the plastic shell to pull it off. Do not pull on
the wire itself. Ensure to pull the connector straight off to prevent damage to the connector and S-terminal. If
any part of the connector is damaged, replace the damaged component.
Some starters use a self-threading bolt to hold the starter cableHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 231