1994 Q45: Alternator removal from the top

[DoinkMobb]

My alternator pulley completely seized up and ate a belt the other day. Fortunately, I ordered a rebuilt OEM unit from ebay months ago. I heard horror stories about removing the alternator, so I was prepared for the worst. It actually wasn't that bad, but most of the time was spent wiggling the damn thing out and then back in.

All I did to extract the alternator was remove the battery and battery tray and take out all the bolts holding the bracket for the external transmission filter. I unbolted the alternator, pushed the transmission filter to the side and fished the alternator out. I looped a bungee cord into one of the bolt holes on the alternator to give me a little help in lifting it up and out - one hand rotating the unit and the other hand pulling straight up. I started to unbolt the AC compressor and the fan shroud, but realized I didn't need to. After I figured out what to do, it wasn't that bad.

Maybe the fact that I have small, feminine hands helped me manuever the alternator around. And I didn't undo any plastic clips or mangle anything in the process. It was kind of a pain getting the alternator back in the place though - when I tried to line up the holes for the long bolt on the right side, the alternator kept getting wedged in place. I eventually filed down the interior edge on the alternator to give me a 1-2 more mm's to work with.

But it's in, the connections are hooked up and all I need now is a new belt.

[qship96]

Would have been a great time to replace the external transmission fine particle filter....probobly the most overlooked filter on the q45, and way more crutial to replace than the internal transmission coarse chunk stopping screen everyone here worries about.

[goody90q45]

Nobody is answering your post because we're all in shock that alternator R&R can be done without removing the AC compressor. It sounds like you may have had the alternator in and out at least twice to file off the corner so it must not be too difficult to move the alternator around. Congrats for trying something different and succeeding. If NICO gave out medals you should get one.

[maxnix]

Or a demerit for filing the bracket. Don't see how that is very clever.

[AlabamaDan]

I don't see where he said anything about filing anything off.

[DoinkMobb]

Nobody is answering your post because we're all in shock that alternator R&R can be done without removing the AC compressor. It sounds like you may have had the alternator in and out at least twice to file off the corner so it must not be too difficult to move the alternator around. Congrats for trying something different and succeeding. If NICO gave out medals you should get one.

Well I filed the edge while the alternator was in, I just rotated it to one side and filed away. Every time I tried to fit the alternator in, it would get completely stuck - like no budging it whatsoever. Filing the edge slightly was the only thing that came to mind.

I dunno, it really wasn't that bad. Now that I know what to do, I bet I could do it again pretty quickly. The alternator whine is gone and my speakers sound much clearer. I'm happy.

maxnix - what else could I have done instead? It was really frustrating having the alternator get stuck everytime I tried to wiggle it into place. I tried for at least an hour before breaking out the file.

[AlabamaDan]

How much did you have to file? I mean before we judge...

[jimbyjimb]

Great work. About the filing; people, don't be jealous he thought of it first. Never put the top bolt back into a Ford starter, I didn't put the obscure 4th bolt back into the wiper motor, OMG! BAD BAD BAD! Making things easier to do by modification that doesn't change the effectiveness of the component or endanger it failing just makes the user SMARTER. Good thinking on filing that edge, I say.

[DoinkMobb]

How much did you have to file? I mean before we judge...

I dunno, not that much. Just enough so I could wiggle it in place better.

[maxnix]

I don't see where he said anything about filing anything off.

I eventually filed down the interior edge on the alternator to give me a 1-2 more mm's to work with.

Personally, I am not a let's leave parts out type of person. I think the engineers had a reason for it being there.

Likewise, FSM procedures are there for a reason.

Personal choice, I guess.