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MARK VII 3G 130 AMP ALTERNATOR INSTALL
Submitted by LSC SS / 09-20-04

  
This is the method I used to install a 3G 130amp alternator in my Mark VII.



You will need the following parts:

1995 Ford Windstar 130amp alternator w/harness. $40 at the junkyard.
175amp Mega Fuse - $5 at AutoZone.
Procedure
Begin by disconnecting the battery terminals and then remove the stock alternator
Bolt the 3G alternator into the lower mounting bracket and you will see how much of the upper mounting tab needs to be removed.
I used a sawzall to trim the mounting tab and then finished it with a small grinder.
The Mark VII upper bolt will not work, so you can either get the proper size metric bolt or or just use a ¼" nut and bolt to hold it in place.

You may need to rotate the alternator case to get the connectors up to the top. That can be done by removing the 3 long bolts from the back of the case and spinning the case until the connectors are in the proper position and then putting the 3 bolts back in.
I used a 6 gauge 48" long battery cable to run a new feed wire, connect the lug end to the starter solenoid, remove the terminal, and install a new lug end in its place. I recommend soldering the new end on.
Install the Mega Fuse as shown. Connect both the new feed wire and the stock feed wire to the end of the Mega Fuse.
Remove the plug from the Mark VII voltage regulator and cut the A & I wires off the plug (I would leave enough on the plug so it can be reconnected if ever needed).
Connect these wires to the A & I wires on the 3G alternator (colors are the same). Again, I recommend soldering these connections.
New feed wire connection at the starter solenoid.
You're done!


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