Battery Drain
Racer
Joined: Feb 2011
Posts: 362
Likes: 15
From: Queensland, Australia
When I changed mine, I loosened the bolt about 4-5 turns before giving the bolt head a good smack. Only then will you feel the bolt is loose and be able to move the alternator around.....
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Pro
Joined: Jun 2011
Posts: 737
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From: Silicon Valley
Targa - I hope this is not a silly question, but how much did you loosen the offending bolt before you hit it with your punch?
When I changed mine, I loosened the bolt about 4-5 turns before giving the bolt head a good smack. Only then will you feel the bolt is loose and be able to move the alternator around.....
When I changed mine, I loosened the bolt about 4-5 turns before giving the bolt head a good smack. Only then will you feel the bolt is loose and be able to move the alternator around.....
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Pro
Joined: Jun 2011
Posts: 737
Likes: 3
From: Silicon Valley
Alternator Out !
I read somewhere brass bushing is heat fitted - so after hammering to no avail on the bolt - I went to harbor freight and got a butane pencil torch
http://www.harborfreight.com/butane-...rch-41169.html
zip tied oil filler tube out of the way - and then put aluminum kitchen foil around the tube and behind alternator rear bracket - just in case. Lit torch - held for 30 seconds or so on aluminum casing around bushing - tapped with 3 pound drift hammer on pulley backed out 3 turns - using 2' (x0.5") aluminum rod I got at home depot (tool rental center cut 3' rod into 1' and 2' length for me) - using towel to protect rear bumper. Bushing moved like hot knife into butter ! Then alternator started swinging out immediately - still a bit fiddly to clear both brackets that hold the alternator bolts to engine - but after 5 mins or so of wiggling - got it out.
Pressed on lock for connector plug and this pulled off easy. Nut holding +ve cable was on a bit tight - used PB blaster and long handle wrench on 13mm socket to get it loose.
Now off to local alternator rebuild shop.
I think with the torch trick - I would have had this thing out in less than an hour (instead of 3 x 1 hour attempts). So hopefully these tips will save someone else some time. Still better than the $1K or so quoted by the shop. And really not hard - after you know how to deal with the bushing. OK time for a beer.
From the picture you can also see the reason for all these problems - Bosch Alternator is "made in Great Britain"
Did they buy Lucas or someone ?
http://www.harborfreight.com/butane-...rch-41169.html
zip tied oil filler tube out of the way - and then put aluminum kitchen foil around the tube and behind alternator rear bracket - just in case. Lit torch - held for 30 seconds or so on aluminum casing around bushing - tapped with 3 pound drift hammer on pulley backed out 3 turns - using 2' (x0.5") aluminum rod I got at home depot (tool rental center cut 3' rod into 1' and 2' length for me) - using towel to protect rear bumper. Bushing moved like hot knife into butter ! Then alternator started swinging out immediately - still a bit fiddly to clear both brackets that hold the alternator bolts to engine - but after 5 mins or so of wiggling - got it out.
Pressed on lock for connector plug and this pulled off easy. Nut holding +ve cable was on a bit tight - used PB blaster and long handle wrench on 13mm socket to get it loose.
Now off to local alternator rebuild shop.
I think with the torch trick - I would have had this thing out in less than an hour (instead of 3 x 1 hour attempts). So hopefully these tips will save someone else some time. Still better than the $1K or so quoted by the shop. And really not hard - after you know how to deal with the bushing. OK time for a beer.
From the picture you can also see the reason for all these problems - Bosch Alternator is "made in Great Britain"
Did they buy Lucas or someone ?
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From: Silicon Valley
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