When I put in my 5.4 we had to grind off the bolt hole on the back so it wouldn't hit the intake. I ate my first belt in a week when the engine went in. Did you do the same?
Yes, I have to grind the alternator so that it fits level. If you do not then it or the belt will fail sooner. I recommend a ford alternator. I am on my second one. Though my first one came off the 95.
Gee, my alternator switched right over to the truck manifold anchor point, and the mounting holes in the block... Recently replaced after 190K, but no sweat... theres a little stamped metal bracket that ties the alt and the crossover together that you gotta use.... works like a charm...
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