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Im trying to remove my altenator on my 1996 Ford Explorer 4.0 liter motor, but I cant even get to the tensioner pulley. It seems impossible.

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Insert a ratchet or other 3/8 drive into hole in front of tensioner, right under alternator,pull to relieve tension on belt and remove belt from alt. Remember how the belt is routed.If you are not going to replace the belt then after getting it off the alt keep tension on it ,so it stays on the other pulleys, touch inside of belt together and hold it together with a clamp (clothes pin or vice grip) or tape. Whatever you use do not apply to much pressure or you may wreck the belt.

Posted on Oct 08, 2010

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One may need to get a breaker bar or a pulley tensioner wrench set from your local auto parts store to easily reach the tensioner pulley. Sometimes at places like Autozone and Advance Auto Parts the tool set can be purchased and returned, essentially, borrowing the tool set from them.
What tool are you using to release the tension from the belt?
--- REMOVAL & INSTALLATION

  1. Disconnect the negative battery cable.
  2. Remove the accessory drive belt. After disconnecting the battery and removing the drive belt, unplug the single wire connector . . . Im trying to remove my - 89682p01.jpg
    . . . then the multi-wire connector from the back of the alternator - integral regulator units lack the single wire 89682p03.jpg
    If the push-on connectors are difficult to remove, use a small pick to disengage the connector latch 89682p02.jpg
    Unbolt the battery (B+) lead from the back of the alternator . . . Im trying to remove my - 89682p04.jpg89682p04.jpg

  3. Label and disengage all of the wiring connectors from the alternator. To disconnect push-on type terminals, disengage the lock tab and pull straight off.
  4. Remove the alternator bolts, then remove the alternator from the engine . . . then remove the altIm trying to remove my - 89682p05.jpgting bolts 89682p05.jpg
    Im trying to remove my - 89682p06.jpglternator from its mounting bracket 89682p06.jpg
    To install:
  5. Position the alternator on the engine.
  6. Install the alternator mounting bolts. On 3.8L and 5.0L engines, tighten the upper bolt to 16-21 ft. lbs. (21-29 Nm) and the lower bolt to 30-40 ft. lbs. (40-55 Nm). On 4.6L engines, tighten both bolts to 15-22 ft. lbs. (20-30 Nm).
  7. On 4.6L engines, install the alternator mounting bracket and bolts. Tighten the bolts to 71-106 inch lbs. (8-12 Nm).
  8. Install the accessory drive belt. Ensure that the drive belt is properly installed on the pulleys before starting the engine.
  9. Attach all engine wiring harness connectors to the alternator.
  10. Connect the negative battery cable.

Posted on Oct 08, 2010

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