Need alternator replacement help

[Paul K]

All:

I cannot get the alternator to break free from the fan housing. Progress thus far...




I have removed all six bolts which go from the alternator through the housing, but it won't budge. I have tried tapping a block of wood with a hammer but no luck, even with WD-40 sprayed on the lugs.

1. Have I removed everything necessary to remove the alternator from the housing?

2. Can these parts be separated by a bearing press?

3. Should I tap the studs or the center of the alternator?

Thanks in advance!

Paul.

[DRACO A5OG]

Bentley guide recommend a puller. I don't know what a puller is.

[HarryD]

Paul,

It is hard to tell from the picture but it looks like the studs are jammed against the holes of the fan housing. If you can hold the housing and rotate the alternator counter clockwise, it might break free. I would try a piece of wood and some light taps with a hammer.

[tsuter]

Since you've tried everything, I'd put the nuts back on those threads 3-4 turns (no thread exposed) then bang them down with a hammer. That'll get you maybe 1/4". Should come out then...
The naysayers won't like it.........

[Paul K]

Update:

All I needed was a bigger hammer. The Bentley manual recommended a puller for removing the fan from the alternator (once it is out of the housing) but I managed to get that off too.

Harry:

I thought that might be the problem, as it did break free on one side first.

Now to re-install with a new alternator...

Thanks,

Paul.

[Paul K]

Done!

For those who are going to attempt their first alternator replacement this winter- the job sucks. Not necessarily technically challenging, but a fiddly PITA! Car now runs great (I am sure the idle is smoother) and the headlights/dash lights don't go bright/dim by themselves!

Thanks for the input guys- much appreciated as always!

Paul.

[HarryD]

Good job. Truth be known, they are all fiddly...

[MOMO3.2]

Paul:

Have you considered having your alternator rebuilt? My alternator failed on my 1987 Carrera a couple years ago and I had a local shop perform a rebuild. It has been perfect thus far. It basically looked as new. I think I paid $60.

Mike

[yelcab1]

The John Walker's method is dropping it over some well placed 2x4s .

I just use a big hammer.

[Formerly Steve Wilkinson]

Just did this job. Take a propane torch and heat up the aluminum/magnesium fan housing around the alternator, then tap the studs of the alternator (with the nuts on the studs) with a rubber or wooden mallet.

And when I installed the new alternator, I put the fan housing in the kitchen oven for 20 minutes first. New alternator slipped into place nicely.

[cab83_750]

2 4x4 and drop the unit.......works like a charm.


Works all the time for me! I think this is J. Walker's method.

[dralph12]

I like the 2 4x4 method. the next time I replace mine I will use that.
I just replaced mine and its was a lot of playing to get it out of the fan housing.
Make sure you have a new alternator to replace it with.
I went thought three rebuilt's from Kragen Auto Parts (all BAD) and then finely got a new one "95 amp" from aasesales@hughes.net for $ 575.00
also take the fan and housing down and have them bead blasted.
A clean Housing makes it a cleaner job to put iit back in.

[NE Ohio 911]

Make sure that there is something soft for the fan and alternator to land on if you use the 2x4 method. I didn't and I now am the proud owner of a new fan from Pelican.

[cab83_750]

Originally Posted by NE Ohio 911

.......... I didn't and I now am the proud owner of a new fan from Pelican.

That was funny! Anyway, sorry about your mishap.


Notes:

1. Before dropping, I removed the fan.
2. I almost tried the 'hammer' routine, but realized that if I were to hit the studs, they might expand and screw up the thread.

[Paul K]

Mike:

Too late, unfortunately. The new alternator arrived from our Host and I figured I'd better get it installed while the core charge reimbursement was still valid. Plus I live in a small town and a rebuilt alternator for foreign car would equal big $$ and a long wait.

Yelcab1:

Instead of dropping it, I set it on the 2x4's and gave the center a good whack with the old Estwing, albeit with a spare scrap of wood in between to minimize damage.

Stephan:

Loved your book! My wife (see avatar) gets worried when there are flames involved- and lucky for me it didn't come to that!

cab83_750:

If I tried that, I'd miss the 4x4's and end up with bits of busted aluminium (sorry, I'm British) all over the floor!

Thanks guys!

Paul.

[Paul K]

Dan:

I used a rebuild form Pelican- hopefully I'll have better luck than you did!

Doug:

Surprisingly, I thought of that- had an old t-shirt waiting below the 2x4's for a soft landing!

Cheers!

Paul.