The regulator case MUST BE GROUNDED on all external Ford regulators. This F540is the product of a liaison between myself and Frank Oropeza of Transpo in Agostino's restaurant in Ft Bragg in 1982. I ranted and carried on about the propensity of B circuit regulators to latch (destruction) when battery reference negative was removed from the circuit. Absolutely positively zero voltage droop from .1 amp field to 20 amps of field current. This reg is .01 stable. And it does not Laurel& Hardy if ground reference is lost.
F) field to one alternator brush. The other brush must be negatively grounded to the case.
S) signal from ignition switch. One of your existing field wires to a brush on the alt is a super quality ignition signal source. Extend it to the regulator S terminal
I) used when an indicator light is needed - an idiot light. Leave unconnected.
A) means a+ battery reference always hot. It doubles as the regulator reference voltage input and source power for the field F terminal circuit. I like the overkill this circuit with a 12-gauge power wire. Now, if you have a superb alternator to battery positive post circuit (which would mean you upgraded it) you can cheat and connect the regulator A terminal to the alternator output stud. Makes the circuit handy, and shorter - no cross compartment runs.
Chop the alternator brush field terminal with dikes. I like to use 14-gauge wire here because of mechanical strength. Solder all terminals and splices. Run to a shiny clean ground.
Run a 14-gauge wire from the regulator F terminal to the OTHER brush terminal on the alternator. Solder.
I SOLDER A 1/4" 12 gauge ring terminal to the regulator case. Remove the irridite plating first. Gob on the solder. Use a plated bolt or wood dowel to keep the holes aligned. 12 gauge wire to the engine in harness with the F and I wires to the alternator. I like external tooth lock washers for all this.
Go online. Go to eBay.
SEARCH Ford External Voltage Regulator Plugs.
There are two types of plugs. Both fit. One is junk.
The plug you want is RED. It has a plastic bridge retaining loop that keeps the plug snapped onto the regulator. The junk one waits until heavy night time traffic, with cloudburst, then slips off the regulator terminals.
The regulator and plug terminals are all cad plated. Smother them with electrolytic silicone grease, including the side where the wires enter the red regulator plug. Smother the riveted terminals beneath the reg. The soldered regulator ground wire is bullet-proof.
Hope this helps. Transpo set the reg for 14.0 volts. Have a ball with the pot.
BUT keep in mind the lid is metal and the stuff inside angers easily.
