Holger B

I used a large screwdriver and a rubber mallet to pry the alternator off its bracket on the right hand side

Holger B

Disconnect wires

jmla

Great pics Holger, it's good to hear that you're back on the road!

Holger B

Not quite back on the road yet...picked up the rebuilt alternator this afternoon and started to reinstall. It's a bitch to get it back in place (which I knew would happen given that I had to pry it out). I pounded on it with a mallet and chunk of 2x4 for over an hour today and it's still not positioned right. (Next time I'd file down the inside of the rear tab a little.) Probably 20-30 minutes work left after I get it bolted in. Should be on the road again tomorrow.

Holger B

Drove the car today. Seems to run perfectly, voltage right near 14 on the gauge and rock steady during 45 minute drive (it continuously dropped before while driving).

I had the shop test the alternator when I brought it in and they said it was fine. Had them rebuild it anyhow and now my problem is solved. If I had to guess, I think the regulator probably went bad.

AllanJ

Thanks for the pics and info!

Cheers,

Holger B

Like I said, it was a bitch to get back in. I think I pounded on the thing with a rubber mallet for hours (and not gently), so I wouldn't have been surprised if it didn't work at all after that. Next time, I'd file down the inside of the rear tab a bit before reinstalling (it'd still be plenty snug). Other than that, the job isn't much harder than putting together some IKEA furniture.

Holger B

One last thought. It seems to me that we're seeing a lot of these failures on cars that aren't very old and don't have a lot of miles, which strikes me as odd for alternators. So, I asked the guy at the alternator shop if it was the heat, vibration, water, etc that was the likely cause. He said all of those have an impact, but that having a weak battery where the alternator has to work harder is what he thinks impacts a lot of stuff they see the most. That would make sense with our cars. My battery was only a little over a year old, but I've been driving it infrequently and don't have it on a charger/maintainer.

AllanJ

Thanks again for the info! I guess I'll be expecting a similar alternator repair in the not too distant future.

jmla

Holger, I was told the same thing! It's nice to know that our notes are similar. I think that I'm going to replace my battery for good measure. My Optima has been fast charged twice after going dead, I was recently told that a fast charge can ruin these batteries?

TurboCup87

Thanks for the write up and pictures. I keep mine on a maintainer much of the time. Hopefully, I can avoid the hours of pounding!

BTW, the alternator was made in GB. That may be the problem if it was an old Lucas plant!

zed996tt

Holger:

Thanks for the write up. Just experienced the same problem.

Zed
2004 GT3

Holger B

Happy to help out. Let us know how it goes.

Is Bosch and their alternators taking a page from the battery manufacturers, where the thing craps out days after the warranty is up?

Crazy Canuck

My alternator doesn't put out rated juice either.

I see a rebuild in my future.

zed996tt

Holger:

Looking at your photos but I don't see the second bolt that holds the alternator in place; is it under the oil filter bracket? Also where is the tensioner? When you say turn the tensioner bolt clockwise, do you mean remove it that way or does turning it that way release tension on the belt while you are applying the clockwise force? You mentioned filing a bit off the tab on the rear..is that area to be filed visible in the photos? Just checking before I get myself in trouble, again. Thanks.

Zed
2004 GT3