Alternator replacement

[Firespirit]

Hey everyone... I'm about ready to tackle replacing my alternator in my '92... I would just like some tips and pictures please! One thing I'm not sure about is releasing the tension on the belt to get the alternator out... I've never replaced an alternator before, so this will be fun Any help and pictures would be GREATLY appreciated :thankyou:

 

[ManySHOs]

Ignore the red circles. The picture is from www.shophoenixproject.com . Loosen the nut on that idler pulley. Once that's loose, insert an allen key into the top stud on that bracket and rotate it to raise the pulley. This removes tension from the belt.

Removing the alternator is accomplished by removing 3 bolts. It's pretty simple. Reinstall the new one in reverse order. Install belt, lower the pulley using the allen key and tighten up the idler pulley (14mm) when done.

Ian

 

[shocar]

I would first take out the battery, remove the battery tray , The tray can be a bit of a pain as the lower 8mm bolts are bit tight to get to. Once you do that you will have more room to work in there.

 

[hawkeye18]

+1 on removing the battery tray. It's not a necessity, but it's a virtual requirement.

 

[Firespirit]

The previous owner told me about taking the battery tray out, but he also mentioned taking out the coolant overflow tank. Would I need to do this?

Thank you guys for the tips and thank you Ian for the pictures and tips! Greatly appreciated!!

 

[USHOMEISHOU]

Definitely remove the battery tray, this gives you gobs more room. as for the overflow tank, I'd say leave it and you shouldn't have any problems

 

[frosho]

I'd take out the overflow tank since it's only held in place by a couple screws, the hose, and the level sensor. Anything to get some more room. And if you can take the tray out easily, I'd do that too, but it's not completely necessary. I've had my alternator in/out a few times now and never removed the tray once. Damn rust...

 

[ManySHOs]

As frosho said, remove anything that's in the way. If you remove the battery tray and find rust, it's not a bad idea to sand it down to bare metal and spray it with primer. Most auto parts stores now sell OEM color matched paint in a spray can. You could always cover up the primer with this paint.

Ian

 

[93rev2sev]

Coolant bottle will not be in the way.

Get your wire wheel, some self etching primer and some black rust-o-leum for the battery tray...once it's out you will want it painted.

Oh, don't bother putting the bottom bolts back in the battery tray...I use door panel hold down pins and just shear the heads off when I take the tray out...you WILL BLEED if you try to put both bottom bolts back.

 

[ManySHOs]

Speaking of the battery tray; it's a good idea to slot the side bolt holes so you don't need to completely remove them next time (if they aren't already slotted). Just use a dremel to cut out the metal from the tray.

I powdercoated my tray black. It looked awesome but I ended up selling it without using it when I relocated the battery to the trunk.

Ian

 

[AREA 91]

I make sure I put the bottom bolts back. If you have ever seen a battery that has moved, you will see a nice slice in the side from the alt pulley.

Slot the batt tray and keep the bolts.

 

[93rev2sev]

OK....so slot it...it's a better idea.

For the record, I HAVE used door panel pins with great success.

 

[Firespirit]

Well, everything went as good as can be expected with a northern SHO...

I couldn't, for the life of me, get the bolts on the battery tray to budge, so I figured that maybe I could work around it. I losened the pulley to slip the belt off, got that rather fine (thanks again Ian for the picture!). I had to take out the breaker bar for the bolt holding the alternator closest to the fender , but finally that came lose just fine... Tried to pull the bolt out and :cuss: hits the battery tray.

I got the cable taken off fine and now I'm stuck with the battery tray and the other bolt holding the alternator in.

I had about half an hour into the job so far and I started right after I got off work. I guess I got a good amount in before it got dark, considering I've never done this before... But hey, so far so good... I've done more complicated things, but this one makes me glad I also have a Vulcan engine.. Those are so small they're easy to work with.

Thank you again to everyone who's helped me out so far!

PS - yes, by the way I really need to sand that battery tray down when I get it off and repaint it or something. There's a lot of rust on it. Where would I be able to find new bolts to put there? The ones that are on there already are REALLY rusted to the point it's hard to put a socket on it. My guess is a hardware store like Menards or Lowes.

 

[frosho]

Hmm I've never had a problem with the tray being in the way... I guess the '94 alternators are a little easier to work with. Good luck getting the rest done.

PS- I know you already loosened it up, but FWIW to anyone else, I use a nifty 14mm ratcheting wrench on that pulley nut... works like a charm.

 

[ManySHOs]

Well, everything went as good as can be expected with a northern SHO...

I couldn't, for the life of me, get the bolts on the battery tray to budge, so I figured that maybe I could work around it. I losened the pulley to slip the belt off, got that rather fine (thanks again Ian for the picture!). I had to take out the breaker bar for the bolt holding the alternator closest to the fender , but finally that came lose just fine... Tried to pull the bolt out and :cuss: hits the battery tray.

I got the cable taken off fine and now I'm stuck with the battery tray and the other bolt holding the alternator in.

I had about half an hour into the job so far and I started right after I got off work. I guess I got a good amount in before it got dark, considering I've never done this before... But hey, so far so good... I've done more complicated things, but this one makes me glad I also have a Vulcan engine.. Those are so small they're easy to work with.

Thank you again to everyone who's helped me out so far!

PS - yes, by the way I really need to sand that battery tray down when I get it off and repaint it or something. There's a lot of rust on it. Where would I be able to find new bolts to put there? The ones that are on there already are REALLY rusted to the point it's hard to put a socket on it. My guess is a hardware store like Menards or Lowes.

Soak the stubborn bolts with PB Blaster, put on a pair of padded Mechanics gloves to protect yourself and put some force into those bad boys. I'm surprised that they aren't coming out. You should be able to take the old bolts to any hardware store to match them up with something. If I recall correctly, the top bolt for the tray has a large washer under the head. Just make sure you mimic that design by getting a similar sized washer with your new bolts.

good luck!
Ian

 

[Firespirit]

:woohoo: Ha ha! I have defeated half of the project. The old alternator is out (and ugly looking, might I add). I ended up taking the coolant overflow tank out and that free'd up a ton of room. To my surprise, the battery tray is all rusty, but underneath is clean as a whistle. I thought it'd be full of rust.

I am taking a break from the cold weather to warm up and then it's back out there to install the new unit.

 

[Firespirit]

SHE RUNS! No more battery light, started right up and everything looks good!

I have her running outside now and am going to take a trip to the gas station for gas, but so far so good!!!!

Thanks everyone for your help!

 

[ffemtcurrence]

can a 92 sho take a 91 or 93 alt.

 

[ManySHOs]

can a 92 sho take a 91 or 93 alt.

It can use the 91 alternator. It can use the 93 mtx alternator if you use the 93's alternator bracket and pulley.

Ian