Alternator Replacement Tips?
 

I'll be replacing my alternator this weekend, looking for any tips, things to watch out for, especially around removing the fan from the alternator shaft, and getting the blasted outer shims to line up correctly on the shaft when replacing the fan belt.

Procedure is well documented in the 101 Projects book, but there always seems to be something that crops up when I get into these projects.

Thanks.

Maybe this?-->

http://www.pelicanparts.com/techarticles/911_volt_reg_replace/911_volt_reg_replace.htm

- Wil

One trick on the outer shims that I use is to not use them on the first pass at torquing the pulley down. After I get the belt set I remove the bolt and add them shims, which now fit neatly over the shaft.

+1 on Wil Ferch's tech article. I did this job for the first time ever a month ago & the article probably saved me several hours of head scratching. Also, take his advice & buy/borrow the ignition wrench set before you start. Removing & installing the nuts on the back of the alternator will be close to impossible with standard length wrenches. There just isn't enough room to turn them.

THE most important thing to remember is to disconnect the battery at the negative terminal before starting any work. If you make contact between the B+ and ground, you will have about an 800 amp arc welder that can kill you or burn the car to the ground.

i used dental floss to hold the shims together last time and it worked great.

All great tips - thanks to all. You have already made this task much less daunting.

I might add that adding a dab of grease on the flat surface of the shims helps hold them "together"...when you stack them.

- Wil

i've done that for years

ON THE ROAD AGAIN!!!!

Thanks to all for the guidance and tips in troubleshooting and correcting my problem. The alternator was indeed the culprit, had it replaced by 10 AM this morning and just returned from the test drive (always my favorite part).

Wasn't it Freud that said "Sometimes an illuminated alternator light is just a bad alternator."

By the way, I took Ronin's dental floss advice for the shims, saved me the hassels I have experienced every time I've had to pull the fan belt.

Thanks again everyone!