How to Replace the Alternator on a 6.0 Power Strokeby Zyon Silket; Updated November 07, 2017
Items you will need
The 6.0 Power Stroke engine was installed on many larger Ford trucks, such as the Ford F-350 built between 2003 and 2006. With 350 horsepower and 650 foot-pounds of torque, the Power Stroke was a 6.0-liter high-horsepower diesel engine capable of towing large loads. Like most vehicles, the Power Stroke uses an alternator to regenerate power from the engine to the battery. When the alternator fails, you must remove it so you can rebuild it or replace it with a working alternator. If you do not replace the alternator, you could damage your vehicle’s battery and possibly the electrical system.
Loosen the negative battery cable connector using a socket and ratchet. Pull the connector off the negative battery terminal to disconnect the power source from the Ford.
Unplug the wiring harness plugged into the back of the alternator. The harness has a push-in lock on each end. Pull up on the tabs to unlock the harness.
Remove the wire nut that secures the alternator grounding wire to the back of the threaded stud on the alternator using a socket and ratchet. Pull the wire off the threaded stud.
Loosen the alternator through bolt that secures the top half of the alternator to the mounting bracket. Loosen the pivot bolt that secures the lower half of the alternator to the mounting bracket. Use a socket and ratchet. Do not remove the bolts at this point.
Push down on the alternator and pull the serpentine belt off the alternator pulley.
Remove the through bolt and the pivot bolt and pull the alternator off the mounting bracket.
Place the new alternator onto the bracket and thread the through bolt and pivot bolt into place using your fingers. Do not tighten them.
Place the serpentine belt over the alternator pulley.
Place the crowbar between the bottom of the alternator and the top of the mounting bracket. Push down on the crowbar handle to create pressure on the serpentine belt.
Tighten the through bolt and pivot bolt using the socket and ratchet while you maintain pressure on the crowbar.
Slide the alternator grounding wire onto the threaded post and secure it using the wire nut, socket and ratchet.
Plug the wiring harness back into the alternator and push down on the locking tab on each end of the harness to lock it in place.
Place the negative battery cable connector onto the negative battery terminal and secure it by tightening the nut on the connector using a socket and ratchet.