April 1999 - 220 amp AIS alternator install

This a rough step-by-step procedure to installing a 220 amp alternator (from AIS) and new alternator bracket (from Ford). Plan on taking an entire afternoon for installation.

1. Locate your alternator. Note that there are 2 bolts that hold the alternator in place. Unbolting these bolts will release the alternator. The alternator bracket bolts to the tensioner (located directly right of the alternator) and the air pump (directly below the alternator).
2. Loosen the tensioner. You will need a ratchet with a long handle so you can produce enough torque to loosen the belt (it's fairly tight). It will snap back into place if the ratchet slips or if you let go, keep this in mind.
3. Loosen the top bolt on the alternator. There is no nut (the bracket is threaded for the bolt), so you can just use a ratchet to loosen it.
4. Remove the belt. Draw a picture for yourself so you know the proper routing of the belt for when you install it again when the new alternator is in.
5. Remove the plug from the top of the altnerator. It may be a tight fit so you will probably have to jerk the alternator a bit to free it.
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7. Remove the alternator.
8. new 220 amp alternator on left, stock 60 amp alternator on right - big difference in physical size!
9. Remove the old bracket. You may have to remove the air pump to remove the old alternator bracket. The alternator bracket bolts to the air pump bracket with one bolt. Install new alternator bracket and bolt it in place.
10. Install new alternator, and bolt into place.
11. Connect positive and ground wires. I used 1/0awg for power and 8 gauge for ground. The 1/0awg was a very, very tight fit, but it was done and has worked without coming loose or rubbing against anything.
12. Do the wiring and hook up the external regulator. Even though the yellow wire from the external regulator is run to the plug that goes to the alternator, you will need to clip this wire and run it directly to the positive on the battery. This is a sensor wire that must always receive constant power. If this wire does not receive constant power, your alternator will not charge the battery/batteries when the vehicle is running.
13. Wiring completed. Make sure to put electrical tape around the positive connection, as this terminals is pretty close to surrounding parts in on the motor. Since it is a live connection when the vehicle is on, we don't want it to short out.