How to Replace Alternator 94-05 Ford Explorer 4.0L
Difficulty: Intermediate · About 60 min · Ford Explorer
Replace the alternator on a 1994-2005 Ford Explorer with the 4.0L engine.
Tools you will need
- Socket extensions
- Flat blade screwdriver
- 14mm socket
- 8mm wrench
- 10mm socket
- Ratchet
Parts and supplies
- Alternator
Steps
- Disconnect the battery
Use an 8mm wrench to disconnect the positive battery cable.
- Remove the serpentine belt
Unclamp and move the intake hose out of the way, use a 3/8-inch drive ratchet on the tensioner to release belt tension, then remove the belt and inspect it for wear.
- Remove the old alternator
Disconnect its wiring harness, remove its retaining clip with a flat blade screwdriver, unbolt it with a 13mm socket, pry it out, then unplug the rubber boot and unbolt the 10mm battery lead.
- Install the new alternator
Bolt in the 10mm lead and cover it with the boot, set the alternator in its mount, bolt it in, clip the retaining clip back in, then plug in the wiring harness.
- Reinstall the serpentine belt
Feed it into place following your belt diagram, use the 3/8-inch ratchet to release the tensioner and seat the belt fully, clamp the intake hose back into place, then reconnect the battery.
Check your vehicle’s repair manual for exact specifications and fit.