Tools You'll Likely Need:
* Socket Set: Various sizes, including metric and possibly SAE.
* Wrench Set: Open-end and/or combination wrenches.
* Ratchet and Extensions: To reach difficult-to-access bolts.
* Pliers: Needle-nose and possibly slip-joint.
* Screwdrivers: Phillips and flathead, various sizes.
* Jack and Jack Stands: Essential for safety. Never work under a vehicle supported only by a jack.
* Wheel Chocks: To secure the vehicle.
* Battery Disconnect Terminals: Disconnect the negative terminal first!
* Torque Wrench: Crucial for proper tightening of bolts.
* Alternator Pulley Wrench: Often needed to remove the alternator pulley. Some use a bolt extractor method.
* New Alternator: Make sure you get the correct replacement for your specific Expedition engine (4.6L or 5.4L).
* Gloves and Safety Glasses: Always protect yourself.
* Shop Rags: To clean up spilled fluids.
General Steps (These are generalized; consult your repair manual):
1. Disconnect the Battery: This is the most crucial safety step. Disconnect the negative (-) terminal first, then the positive (+).
2. Access the Alternator: This usually involves removing some components to get to the alternator. On the Expedition, this might include:
* Removing the serpentine belt: You'll need to use a belt tensioner tool or appropriately sized wrench to loosen the tensioner and remove the belt. Diagram the belt routing before removal to ensure correct reinstallation.
* Removing the alternator mounting bracket: This might involve several bolts.
* Disconnecting electrical connectors: Carefully disconnect the wiring harness connectors from the alternator. Note their locations for reinstallation.
3. Remove the Alternator: Once the belt and mounting components are removed, carefully remove the alternator from its mounting location. It may be heavy.
4. Install the New Alternator: Carefully install the new alternator, ensuring it's seated properly in its mounting location. Tighten all mounting bolts to the manufacturer's specified torque.
5. Reconnect Electrical Connectors: Reconnect the wiring harness connectors to the new alternator, ensuring a secure connection.
6. Install the Serpentine Belt: Carefully route the serpentine belt back onto the pulleys, following the routing diagram you made (or the one in your repair manual). Ensure the belt is properly seated and tensioned.
7. Reconnect the Battery: Reconnect the positive (+) terminal first, then the negative (-) terminal.
8. Test the System: Start the engine and check the alternator output voltage using a voltmeter. It should be around 13.5-14.5 volts. Check all your connections and belts to make sure they didn't loosen after you started the truck.
Important Considerations:
* Repair Manual: A Haynes or Chilton repair manual for your specific year and engine is highly recommended. These manuals provide detailed instructions with diagrams.
* Safety First: Always prioritize safety. Work in a well-lit area, use jack stands, and disconnect the battery before starting any work.
* Proper Torque: Use a torque wrench to ensure bolts are tightened to the correct specification. Over-tightening can damage components.
* Professional Help: If you're not comfortable performing this repair yourself, consider taking your Expedition to a qualified mechanic.
This is a general guide. The exact procedure may vary slightly depending on your specific 1997 Ford Expedition model and engine. Refer to your repair manual for precise instructions and safety precautions. Attempting this repair without the proper knowledge and tools could result in damage to your vehicle or personal injury.
