Want to be

Is there a trick to installing the unit? I can't seem to get the first bolt location installed. I have attached a photo to ask if this thread insert supposed to hang out? Maybe it's just my angle. Thoughts? It can't be this hard. Lol

See third photo on next reply.

Want to be

Actually this photo.

Avar928

The alternator mates to the power steering pump bracket and you slot the long 17mm bolt through. This will be tricky cause you need to get all the holes lined up while still holding that alternator up. Best to use something to lay it on to adjust such as perhaps a floor jack because it is rather heavy and that bolt can be a big pain to get right.

Want to be

I can't seem to get the alternator on the steering pump. Seems too tight.

MainePorsche

What Avar said, to be supporting it from below. If I remember correctly, I had my sous chef (my son) from below hold the alternator in the exact position while I lined up the bolt axis from above using a telescopic mirror. I had to be above it for I had to lift the fan shroud slightly in order to get the long supporting pivot bolt in.

Avar928

Just work it in. It's supposed to be tight when it's on the bracket.

Want to be

Your son had the harder job lol.

I doubt my ten year old can lift it.

I'm guessing I need to remove the box and get directly underneath it.

It must be the angle because I can't even get to the point of inserting the bolt.

It's a tight installed. The alternator needs to be a couple mm less in width.

Avar928

I actually installed mine from the bottom, holding the alternator up with one hand and navigating the bolt with the other. It is a PITA for something so simple. Use a floor jack and spare your arms of the work.

Use a screw driver to "feel" around once you get it into the bracket to make sure it's centered.

Want to be

Thanks. If I can get the darn thing over the bracket I'm home free.

Kevin in Atlanta

1. Look at the picture in post #2. You see that rear alternator mounting hole? Tap that out flush to the face of the alternator mounting hole. That should cure the tightness and make it easier to mount.

2. I use the sparkplug rod to temporarily mount the alternator in place and then tap it out with the bolt as I permanently mount the alternator.

dr bob

While the alternator is out and accessible, put the long bolt through the alternator and thread it in until there's maybe 1/8" of space left to tighten. Small hammer, tap the end of the bolt in the rest of the way.

Installed, the bolt draws that rear threaded bushing through the ear, clamping the console bracket between the bushing and the front ear. When you drop the alternator out of the bracket, you leave that bushing in the 'clamped' position or very close. Tapping it back towards the rear opens the clearance enough to let you slide it back up around the console bracket. Having it relatively free makes it possible to adjust the position manually as you try to get the bolt through and lined up with that bushing again. There isn't a lot of bushing movement available, but it's enough to let you reassemble.

Rob Edwards

The biggest 'trick' to remounting the alternator easily is to get a C-clamp and two sockets- one with a diameter just greater than the bushing in the rear alternator mounting flange, and one just smaller. put the smaller socket on the 'front' face of the bushing, and use the C-clamp to press the bushing back into the flange, so the alternator easily slips over the mounting cassette. Makes life much easier. Learned this trick from Dr. Bob a couple of moons ago.

Pic of the bushing in the rear flange, you can see it hasn't been pushed backwards into the arm yet.

Want to be

Awesome. Something so simple. I'll try and advise if I'm successful.

Want to be

Just tried it. After few tries I was able to get the bolt through. The not so funny part, the nut feel off twice and I had to remove the long bolt. Anyways the bolt is installed! Dr. Bob do you accept FSA for payment? You sure are a life saver. Thanks again. Ps the procedure opened the area by two mm. . Roughly 82 mm

928wolf

Thank you for having this problem first! I am attempting the same install this weekend and sure enough, my new (used) alternator has the same - apparently easily fixed - issue. I'm sure this will reduce the number of f-bombs dropped on this job by at least half.

Thank you again Rennlist!