3G Install Tech
In 1996 Ford publicly recognized the fire hazard caused by the 2G alternator and released TSB 96214. This alternator design caused increased resistance and heat which could damage the wire harness and alternator. A small percentage of vehicles actually caught on fire!
Fords 3G alternator was a giant leap in technology and quality. The 3G was internally regulated, used two internal cooling fans, sealed bearings, and had a superior battery stud. The 3G’s were more efficient, and produced more amperage at idle than any of its predecessors.
Click on the Pictures for a Larger View
You need to connect the single wire left on the harness to a wire that is HOT with the key in RUN. Ford has used a Green/Red wire on their vehicles for over 50 years. So it’s simple to find that wire that went to the old alternator and use it now.
The last thing you need to do is connect the 2Ga battery charge cable and mount the Mega-Fuse. The Battery charge cable should be bolted directly to the batteries positive post, or you can follow the positive battery cable to the starter solenoid and bolt it there.
If you purchase a 3G alternator from other sources it typically won’t have threads.
You will need to use a longer 3/8″ bolt and nut.
LINK: Our 3G alternators are threaded and come with the correct M8 bolt
Or drill out the mount hole and install a Heli-Coil.