Replacing the alternator on a 1994 4.9 everything came apart fine EXCEPT the three wire plug that is on the bottom side of the alternator. I have tryed everything I even have the alternator in halve and I still can't get it unplugged is there a trick?
Tim C

 

Sounds melted. Might start hitting salvage yards or e-ebay.

 

If it is a gen 2 it got hot.
The gen 2 is actually a fire hazard. Google it. I still have a gen 2 in my truck but not for long.

 

Yeah, my gen 2 melted that plug twice.

 

I thought I was going to loose my truck driving down the road. I pulled over, opened the hood and had a foot of fire coming out of my alternator.
I was told that I must use the dielectric grease. The grease comes with most new alternators.
You might have to cut the plug off and replace it.

 

Google gen 3 up grade.

 

That might be the best upgrade you can do for your truck

 

http://fullsizebronco.com/forum/showthread.php?t=55169

 

Probably the only upgrade I haven't done.

 

Thanks everyone
After reading this and looking real close it was melted or it was one piece to begin with.
After reading the instructions that were laying in the bottom of the box apparently there was suppose to be a new plug included in the box and of course I ordered this from an on-line parts house. So I just had a wonderful discussion with a young lady at a call center somewhere in India that read right off her reply instruction sheet and now I'm resting so calm and secure knowing I have a complaint claim on file.
Tim C