Tips, hints etc....
I used the alt off of a 97 taurus. The 7.0 pivot mount is damn near a bolt in on our trucks, replacing the 1g unit. Slight adjustment to the swing bracket(move it down a bit), and the alternator spacer, (i had to knock about 1/8 off it to get things to line up correctly) I used a single groove pulley off a 2G alternator. This pulley had a small spacer behind it, so no machining of the pulley was needed. This 3g fits, amongst other things , a 99 mustang with a 3.8 V6. The Motorcraft # is a GL477RM. If you go to the motorcraft website, you can search that # & take the list of all the applications when you go. Makes searching that much easier. When you get the alternator, get the small harness' that come with it. If you slice the factory harness open, you should be able to get at least 18-24" of this harness from the alternator. This will be handy when it's time to wire the unit into your truck. There is also a large (4ga) charge cable. get all of it you can. I used the existing B+ from the alternator in my truck to feed the chassis harness, and the large charge wire from the donor was run thru a 125 amp Midi fuse, to the hot side of the solenoid. The green/red exciter wire from the existing harness connects to the "I" terminal on the 3G unit. The "A" terminal should run to the hot side of the solenoid. This is the voltage sense wire. My setup is a 302 & i had to get a belt about 1"longer to get the adjustment where i wanted it.
Fan mounting was fairly easy. I slit some 1/4 fuel line to "cushion" the fan housing where it fit next to the radiator. Glued that in place with some black weatherstrip adhesive & i was ready to go. When you get the fan, make sure you get the connector plug & at least 12-18" of wire.(the connector is available thru motorcraft, if you need one, but they're kinda pricy..) On the fan i got, orange is high speed, blue is low speed, black is ground. Maker SURE you have the black wire on a good clean ground point. Right now, i have the fan on a toggle switch,triggred thru a 30 amp relay ,to run low speed only. The wires are all 10ga to power/ground the fan. Be advised...these fans on high speed pull OVER 80 amps to start, settle in at about 50-53 on steady state. You need a 70 amp relay, minimum and 8ga wires if you're gonna run this bad boy on high speed. Do NOT connect the low speed & high speed wires together, this gets some sort of wierd mid speed operation that the motor doesn't seem to like at all. Each application is different, but you should be able to use at least one mount from the fan to tie directly to the frame of the radiator. The rest of the mounting involved making some simple brackets to catch the remaining 3 mounting points on the fan. When handling the fan, do NOT pick it up by the fan blades...trust me on this one
The whole swap could have been done in about 4 hours, but, since i'm a picky bastid, and fairly anal about how things are wired, i've got about 6 in it, all told. I now have a truck that has brighter headlights, more voltage, less horsepower drag, a Badass cooling fan, and all for less than about 60 bucks. Bonus points..it"s all "recycled" stuff
Sorry this is so long...but i'm fairly pleased with the way things worked out, and wanted to share..
