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How to Replace Alternator 94-05 Ford Explorer 40L

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How to Replace Alternator 94-05 Ford Explorer 40L

Created on: 2021-01-16

Battery ran down? You might need a new alternator! Check out this video to learn how to replace it in your 94-05 Ford Explorer

  1. step 1 :Disconnect the battery
    • Use an 8 mm wrench to disconnect the positive battery cable.
  2. step 2 :Remove the serpentine belt.
    • Pull the intake hose back by unclamping it and moving it out of the way.
    • Use a 3/8 drive ratchet handle on the belt tensioner to release tension on the serpentine belt.
    • Remove the serpentine belt and inspect for flaws and wear.
  3. step 3 :Remove the alternator
    • Disconnect the wiring harness from the alternator.
    • Remove the clip using a flat blade screwdriver
    • Unbolt the alternator using a 13 mm socket and ratchet.
    • Pry the alternator out.
    • Unplug the rubber boot and unbolt the 10 mm battery lead.
  4. step 4 :Install the new alternator.
    • Bolt in the 10 mm socket lead and cover with the boot.
    • Place the alternator in its mounting.
    • Bolt in the 13 mm bolts.
    • Clip the pushclip back in.
    • Plug in the wiring harness.
  5. step 5 :Install the serpentine belt
    • Use your serpentine belt diagram to feed the serpentine belt into place.
    • Use the 3/8 ratchet to fit the serpentine belt on all the way by releasing tension off the tensioner.
    • Clamp the intake hose back into place.
    • Reconnect the battery.

Tools needed for replacement

  • Ratchets & Related

    Socket Extensions


  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    14mm Socket

    10mm Socket

  • Wrenches - Metric

    8mm Wrench

Installation Video
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Brought to you Your source for quality replacement parts and the best service on the internet. Hi, I'm Mike Green. I'm one of the owners of 1A Auto. I want to help you save time and money repairing and maintaining your vehicle. I'm going to use my 20 plus years experience restoring and repairing cars and trucks like this to show you the correct way to install parts from The right parts installed correctly, that's going to save you time and money. Thank you and enjoy the video. In this video, we're going to show you alternator replacement on this '98 Explorer, same as any '97 to '01 Explorer with a V6 motor.

Tools you'll need are an 8 millimeter wrench, flat blade screwdriver, regular and small sizes, 14 and 10 millimeter socket with ratchet extension, and a 3/8 inch drive ratchet handle. Disconnect your negative battery cable with an 8 millimeter or a 5/16 wrench. You're going to want to pull your intake hose back which is fairly easy. You will loosen up this clamp here and then you'll want to unclamp your filter box. Okay, and then pull that off of your entire body. Lift this up then you can just kind of flip this up. Okay, now to remove the belt, right here is your belt tensioner and you'll want to take a 3/8 drive ratchet handle and then just square it whole right in the tensioner.

I put my wrench down in there, push down and you could see the belt loosen up and then slide it right off of the either pulley and let your wrench back up. Then you can just take the belt off, all the components, reach down and flip it off of the crank shaft and it comes up and off. Okay, with the hose out of the way and the security belt off, it's pretty easy to get in here. Just using a screwdriver to kind of widen here and disconnect that one. Use a little screwdriver and put it right in here. You disconnect that one. Okay, although this one is actually a bolt which what we'll do is we'll remove the alternator first to make it easier to get to that one.

Okay, then we'll clip here. You're going to use a screwdriver and then pry from underneath. Okay, the 13 millimeter bolts, got to use a little trick for leverage here. Got my padded ratchet, take a big wrench here and hook it on there. This makes it nice and easy to get leverage. Okay. Just to have an extension, same thing right down here. Some leverage to get it moving. Okay, bring it up. Remove that. Okay, make sure you have your battery disconnected here because if you don't, you'll get some sparks. Pry this boot up and off. I'm going to place the 10 millimeter socket here and obviously once you get this off, the alternator comes right up and out and I'm just doing this for a demonstration so there's nothing wrong with this alternator. I'm going to put it right back down and in.

Okay, note that this has little kind of geeks on it so either the harness can go up this way or down that way, you want it up. Okay, as the alternator's sitting in here with these two things here, you'll want the wire coming out this way. Oops, just make sure you put that bolt through this bracket. Reconnect your tube connections. I like to get them really tight but really tight with this wrench. Okay, now you put your belt on. Put this clip back in. Work it back. Put the belt back on, very important. Here's your belt diagram. It shows how the belt is routed. What we want to do is make a lot of loop and work it around the crack shaft here first and then we'll work around everything else.

Okay, make that loop and I want to make it tight and past the belt under the shaft for the fan a little bit just to get it to your other hand, then get it up and under the crank shaft or around the whole crank shaft. Move it on top. Take the belt up and over the water up around the car steering pump and AC compressor. Okay, over there alternator and into the tensioner. Then you're going to press on in here, make sure we wind it up good, well. Then push your tensioner down and in with a wrench and slide the belt underneath the wrangler and we're all set. Flip the other end back over, push it over here, push it back in here. There's three tabs over here, just make sure they're going to the right slots. Put it back on, make sure it's pushed on there well, and tighten your clamp back up.

Okay, make sure all these connections are still good and we're all set. We hope this helps you out. Brought to you by Your source for quality replacement parts and the best service on the internet. Feel free to call us toll-free, 888-844-3393. We're the company that here for you in the internet and in person.

Tools needed for replacement:

    Ratchets & Related

  • Socket Extensions
  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 14mm Socket
  • 10mm Socket

  • Wrenches - Metric

  • 8mm Wrench

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