Alternator Removal - Houston, we have a problem
 

Hi gurus,

I know you guys can help, so here goes.
My alternator went south this weekend (noisy bearings, no charge, etc). So I am in the process of removing the alternator to see if it can be repaired before spending (gulp) 340 bucks for a new one.
Everything is undone and unhooked except ONE nut holding the air guide to the back of the alternator. The problem is that this nut is stripped, it just just turns around and around and does not loosen. To make matters worse, it is the bottom left one with the ground strap attached, hard to reach! AARRGH, these weird little things always seem to happen to me!! :mad:
So any suggestions, gurus, on getting this nut off? I was going through the parts diagrams and it looks like the bolts these nuts attach to are the long alternator bolts that attach the alternator to the fan shroud. Any ideas on how to get the fan off the alternator shaft while still in the shroud? BFH? This would at least give me access to the bolt so I could hold it with a wrench. If this does not work, I was thinking of somehow using a dremel tool to either cut the nut, or etch a groove in the end of the bolt to hold it with a screwdriver. But, this would be in a very small space, so I am not sure if these options will work.
Thanks gurus!!!
Craig

Can you reach....
 

Can you reach the other end of the grounding strap and take it loose from there ....then the whole unit should come out. My grounding strap is on the engine case I belive on the second bolt back. Although with my patience I would have ripped it out by now and repaired what ever I broke...especially if it was plastic.

Good luck...

if you can possibly wiggle the fan off, then you can get at the head of the bolt. worst case, you can break the air guide just around that last nut so you can remove the wires. it'll live just fine less one attaching point.

JW is right. if you just cut a slot in it, well two slots, you can slide it out. then later, with a slightly oversized washer, you can even use that attachement point. i have poked around alot of cars where lazy mechnics just attach the ones that are easy to reach. i like using them all, it pulls the alt into the housing evenly.

THanks for the replies guys, you have given me hope:)

Doherty: LOL! I did just that, removing the case bolt to take off the strap. But I realized even before I was done ( imagine my chagrin) that it would not work because the alternator wires that feed through the air guide were still attached to the alternator! I took it off anyway because I will be able to re-torque the case nut easier once the fan shroud is out of the way.

JW and Vash: I will try to wriggle the fan off first, although not a lot of wriggle room still being in the shroud. If that does not work I like the idea of cutting the air guide to slip it off. I think there even enough room to do that with dremel tool.

I will keep you posted as this saga continues.

Thanks! SmileWavy
Craig

silly suggestion - please ignore

Update.
Tried wriggling the fan loose last night, did not work. Tapped on it, banged on it with a rubber mallet, banged on it with a piece of wood and small sledge, tried prying between the shaft and fan housing, tried tapping it from behind, no loosening anywhere. So it looks like on to plan B, cutting around the air guide. Was trying to avoid this, but it looks unavoidable.
Now I just have to find my dremel tool after moving, it is still in box somewhere...:confused:

Any other suggestions are welcome!
Craig