S8ilver

Attempting to R&R my alternator, but cannot break the fan nut loose to be able to access the tensioner bolt. Soaked it overnight with PB, but all I can seem to do is break free the 3 10mm bolts on the pulley. I can get a ratchet on the tensioner bolt from below, but can't get enough torque with one hand to have enough slack to slip the belt free. I've tried shocking the bolt with a mini sledge.

Any quick tricks I'm overlooking?

S8ilver

Ok finally got the belt free with a homemade extension. Next issue, the alternator. The S8 only has one upper and one lower bolt correct? A 1/2" lower bolt and 8mm hex top bolt. Got both bolts out...can get the alternator to swivel but will not drop out. Just one of those days i guess...

S8ilver

I'll just keep replying to my own thread until I'm finished!! The alternator took a LOT of persuasive wrestling and cursing. It finally came loose. Bearing swap nearly complete...the rear bearing had a seal failure with grease leaking out and was nearly locked up...front sounds like a coffee grinder. Removing the front pulley was a bear...24mm box wrench and M10 to keep shaft locked...then the frozen screws on casing. Sigh. I had to use an impact screwdriver here. Brushes about 1/3 worn...still debating whether to mess with them or just pop in the regulator that came with rebuild kit. Slip rings fine. I just wish a replacement OEM alternator wasn't so damn expensive.

S8ilver

Was a bit hard to believe how much gunk had accumulated!

All is quiet under the hood now.

brittcrowell

Yea those alternators are pesky to remove. Every time I've had to do a coolant pipe (4 engines) the alternators have been stuck in there pretty good!
Nice job on the RR of the alternator.
Where did you get the rebuild kit?

Britt

S8ilver

Most of the parts came from an Irish supplier on Ebay (Gold Lion) ~$25.

Search Ebay: ALTERNATOR REPAIR KIT FOR BOSCH "INTERNAL FAN" TYPE ALTERNATOR

The kit came with everything except has the incorrect front bearing. For that you will need:

B17-99D-2RS-AB-Alternator-Bearing-17x52x17-Sealed-Ball-Bearings-17292 ~$18

If I had to do the job again, it'd be a snap. Luckily I had purchased a set of gear pullers which made quick work of bearing removal. For reassembly, the rear bearing went on with a deep socket and rubber mallet. The front bearing was even easier. I placed the housing in the oven at 300 for about 20 minutes and the bearing in the freezer. It was comical how easily it dropped back in.