Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD1987CUTAWAY 7.5 LREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALCHARGING SYSTEMSALTERNATOR - MODELS W/EXTERNAL REGULATOROVERHAULSIDE TERMINAL MODELSDISASSEMBLY

1987 Ford Cutaway 7.5 L

Side Terminal Models: Disassembly

1987 Ford Cutaway 7.5 LSECTION Disassembly

Mark housings and stator for reassembly. Remove through bolts. Separate front housing with rotor from rear housing and stator. Do not separate rear housing from stator. Remove drive pulley nut, lock washer, pulley, fan and spacer from rotor shaft. See Fig 2.
Remove rotor from front housing. If bearing is dry or damaged, remove front bearing retaining screws. Support housing near bearing boss and press bearing from housing. Unsolder stator leads from rectifier assembly with 100-watt soldering iron. Use care not to apply direct heat to rectifier.

Fig 1: Assembled View Side Terminal Brush Holder
Courtesy of FORD MOTOR CO.
Remove stator from rear housing. Unsolder brush holder from rectifier. Remove capacitor lead from rectifier screw. Remove rectifier retaining screws from rear housing. Remove terminal nuts and insulators from outside of rear housing. Remove rectifier from rear housing.
Remove brush holder, brushes and 2 rectifier insulators from bosses in housing. Clean sealing compound from rear housing and brush holder. Remove capacitor from rear housing. If necessary to replace rear bearing, support rear housing near bearing boss and press bearing from inside of housing.

Fig 2: Exploded View of Side Terminal Alternator

Courtesy of FORD MOTOR CO.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.