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> Alpha alternator, small PIA, or major PIA?
bhorste
post Aug 30 2013, 01:10 PM
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Still haven't gotten the bolt out. Maybe some JB weld on a grade 8 bolt and stick it to the end of the broken bolt? The alternator (whose bearings are INDEED seized) is just flopping in there by this bolt. Vinnie and Bob, I'm looking specifically at you guys for some real suggestions.


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Bobzilla
post Aug 30 2013, 01:59 PM
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Take the side engine mount loose and drop it down so you can get to it easier with an e-zee out?


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bhorste
post Aug 30 2013, 03:48 PM
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QUOTE (Bobzilla @ Aug 30 2013, 02:59 PM) *
Take the side engine mount loose and drop it down so you can get to it easier with an e-zee out?


I'm not sure just how far down it'll drop with the mount loose. Plus, that won't change its position relative to all the other crap in the way (halfshaft, wire for O2 sensor, etc.). Might give it a try later this evening, with a smaller board between jack/oil pan (oh yeah, have to work around that nonsense, too).


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bhorste
post Sep 14 2013, 02:42 PM
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This thing is still fighting me, which is remarkable. I've snapped 3 drill bits on this project (including a DeWalt cobalt 5/16 bit) but chewed up most of the threaded tab on the alternator... and it still won't let go. I don't know whether to smash something or just sit here and cry quietly in frustration.

Any futher hints/suggestions?


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Vinnie
post Sep 14 2013, 03:38 PM
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So #7 bolt is still stuck in there?

That oil pump bracket - that's what holds it all onto the engine right?

Worst case scenario - VERY worst case....

How comfortable are you doing timing belts?




You get that bracket off - you can put it into a vise very lightly tight - drill it out or replace the bracket.

One way or another - not all hope is lost - you've got this.


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bhorste
post Sep 14 2013, 04:31 PM
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I'm trying to get this finished so I can move on to the timing belt/water pump... and I'm not terribly comfortable trying to take that bracket off. It looks like it's held on by oil pan bolts among others.

The big problem is just that there is NO room anywhere around it. I'm going to have another go at it with a smaller drill bit in a little here... need a quick post-dinner nap. I WILL have that damn alternator in my hands this evening, so I can devote post-work, pre-Lions time to the rest of the job tomorrow... okay, and probably during-Lions time as well as post-Lions time. Really gotta get this job done; the wife goes back to work in just over a week.


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bhorste
post Sep 15 2013, 03:01 PM
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Okay, we've got ourselves a good news/bad news situation:

Good news: the alternator is no longer attached to the block.
Bad news: it is not out of the engine bay. Also, I had to use a cutoff wheel to cut through the threaded tab.
Good news: I think there's a way to get it out.
Bad news: it involves removing the oil filter. Also, not sure if I'll be able to get the new alternator in this way.

Will be heading back out in a bit to try to pull it... but I will probably just get a new oil filter for the car (it's about due anyway) and try to make it happen that way.


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bhorste
post Sep 15 2013, 05:09 PM
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The old alternator is OUT! It involved undoing the motor mount and moving the motor up and down about 6 times, but I managed to drop it out the bottom. Just took it back to get the core; they never even opened the box to look at it. WINNING!

Of course, now the real fun will be getting the new one in, with all 3 tabs intact.


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bhorste
post Sep 17 2013, 10:15 PM
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The new alternator is IN!!!! A big shout-out of thanks to member hourang for driving the hugely long distance (just down the block) to be an extra set of hands and helping to fnagle the beast into position and put the accessory belts on (which was an entirely different bear of an issue).

After having to do some creative engineering to get the new battery to fit (new one is ~1" shorter than the old one, not enough threads on the hooks) - which involved getting out my brand-new B&D circular saw and cutting down a piece of wood to go under the battery - I buttoned everything back up that was needed to make the car run, pressurized the fuel system, turned the key and...

IT PURRED LIKE A KITTEN!

I'm amazed the bearings on that alternator didn't fail sooner, with all the noise it made. The new one is quiet, there's no belt squeal, it's very nice.

The water pump/timing belt are on hold until I can find another weekend to take care of the whole deal. The important thing is that the wife has her car back on the road, which she will after I re-install the splash guard and take it down off the jackstand.

Overall, I'd have to answer my initial question by saying, yes... changing that altertnator was a major PIA.


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slowgls
post Sep 17 2013, 10:23 PM
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Glad you got it together.


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bhorste
post Sep 17 2013, 10:34 PM
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QUOTE (slowgls @ Sep 17 2013, 11:23 PM) *
Glad you got it together.


Thanks... not looking forward to eventually getting after the timing belt/water pump. The motor mount tab on the block is right above the water pump pulley. Don't think it comes off, either. Ought to add intrigue, if nothing else.


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