Tools You'll Need:
* Socket wrench set (metric): Various sizes, including those for the alternator bolts and battery terminals.
* Ratchet and extensions: To reach difficult-to-access bolts.
* Wrench set (metric): For potentially stubborn bolts or as backup.
* Pliers: For disconnecting electrical connectors.
* Screwdrivers (Phillips and flathead): Potentially needed for various trim pieces.
* Jack and jack stands: Essential for safety and access.
* Wheel chocks: For added safety.
* New alternator: Make sure you get the correct replacement for your vehicle.
* Wire brush: For cleaning battery terminals.
* Battery terminal cleaner: To prevent corrosion.
* Gloves: To protect your hands.
* Safety glasses: To protect your eyes.
* Shop rags or paper towels: To clean up spills.
Procedure:
1. Safety First: Disconnect the negative (-) battery terminal. This is crucial to prevent electrical shocks and short circuits. Then disconnect the positive (+) terminal.
2. Access the Alternator: The alternator is typically located on the front of the engine, near the bottom. Access will vary slightly depending on the exact year and model, but generally, you'll need to:
* Raise the vehicle: Securely jack up the front of the vehicle and place it on jack stands.
* Remove the wheel well liner (or parts of it): This will give you better visibility and access to the alternator. Some plastic fasteners may need to be removed carefully to avoid breaking them.
* Possibly remove some components: Depending on your vehicle, you may need to remove the power steering pump, or loosen the AC compressor to gain better access to the alternator mounting bolts. Again, consult your repair manual.
3. Disconnect Electrical Connections: There will be at least two electrical connections to the alternator: a large wire and a smaller one. Carefully disconnect both connectors. Take pictures or make notes of their locations to ensure correct reconnection.
4. Remove the Alternator Bolts: Locate the bolts holding the alternator in place. These are usually two or three. Use the appropriate socket and ratchet to carefully remove them. Some bolts may be difficult to access.
5. Remove the Alternator: Once the bolts are removed, carefully remove the alternator. It might be a bit heavy, so be prepared.
6. Install the New Alternator: Carefully align the new alternator with its mounting points and bolt it in place, using the same bolts you removed earlier. Tighten them to the manufacturer's specified torque.
7. Reconnect Electrical Connections: Reconnect the electrical connectors to the new alternator, making sure they are securely fastened.
8. Reassemble Everything: Reinstall any components you removed to access the alternator (wheel well liner, power steering pump, etc.).
9. Reconnect the Battery: Reconnect the positive (+) battery terminal and then the negative (-) terminal.
10. Test the System: Start the engine and check the charging system voltage using a multimeter. The voltage should be around 13.5-14.5 volts when the engine is running. If not, there may be a problem with the new alternator or other parts of the charging system.
Important Considerations:
* Belt Tension: When reinstalling the alternator, make sure the serpentine belt is properly tensioned. A belt tensioner tool is often recommended for this.
* Torque Specifications: Use a torque wrench and follow the manufacturer's specifications for tightening bolts. Over-tightening can damage components.
* Repair Manual: A repair manual specific to your vehicle's year and model is highly recommended. It will provide detailed instructions, diagrams, and torque specifications.
This is a general guide. Specific steps may vary depending on your vehicle. Always prioritize safety and refer to a repair manual for detailed instructions specific to your 1996-1999 Ford Taurus/Sable. If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic.
