Alternator Removal Help

[varnco]

This started in another thread, but want this to be more relevant, as the original question was answered. It's the fix that I'm having issues.

I'm trying to remove my alternator (4 hours now)...

I have 2 issues:

1. I can't remove the connector... I don't want to break it.
2. The manual doesn't mention, but there's a wire harness attached to the back of the altnernator... how does it come off?

I've attached pictures.

The connector that I can't get off.. no idea how it's supposed to release, and I can't find another in the engine that looks like it so I can figure it out...


The wire harness, and how it's attached to the back of the alternator

There's a flat piece of metal attached to the back of the alternator that the black housing slides onto and locks in place. It won't budge.



Any help on how to get these 2 gremlins out, and I'll maybe have my alternator out. I'm about ready to get it towed to the nearest shop and have them do it. This is ridiculous!

[varnco]

I guess direct linking didn't work.. here they are:

https://www.dropbox.com/s/aw962nj8c360k ... r.jpg?dl=0

https://www.dropbox.com/s/wtyrxqp1ipaqf ... e.png?dl=0

[Buzzman]

I'm about ready to get it towed to the nearest shop and have them do it. This is ridiculous!

That's what I did.
I took one look at the job and didn't even attempt it.
Paid $120 to have it done at the shop.
(I presume you're trying to take it out from the bottom and not the top.)

FYI, as for posting pics, download them to a hosting site like photobucket, and then copy and paste the url into your post.

[varnco]

Buzzman,

Thanks for the reply.

I am trying to take it out from the bottom, but I can't even try to take it out because I can't get it unhooked from the plug and the harness. I don't k now how the connection is released and I have no idea why there's a wiring harness attached to the back of the alternator. The stupid service manual doesn't say anything about how to remove the alternator, except provide a diagram that shows 2 bolts to remove...lol.

Did they install your alternator? Was this someone you knew?

Dropbox works (right?), but I guess the img img tags don't like https.

[towncarblue]

ive done the alt plenty of times
what i do is , take out the battery,disconnect the top radiator hose, take out the fan shroud ,remove the bolts connecting the alternator to the engine
the i tilt it a little. use a flathead screwdriver to move the clip { if the alt been there for a while
that clip gets hardened into place } . then i use my fingers to press down on the clip while i wiggle it
back and fourth { in your pic the push clip is obscured by the black wire }.
when all the wires are disconnected remove the two top radiator brackets so you can push
the radiator up while navigating the alt around the sway bar.
also... look at the fan blades . between two of the blades is a bigger gap . thats how you maneuver it through the fan blades.
or just remove the fan clutch

[ipeelscats]

Wow, I thought the alt on a 98 QX4 was a pain. As mentioned earlier, the push clip in the first pic is on the left side of the plug and will likely be stiff. The black mount in the second picture separates at the flat part on the right. The 2 halves snap together and can usually be separated with a flat head screwdriver. Personally, I would take it to a reasonably priced shop rather than go through all that mess to get it out.

[Buzzman]

Buzzman,

Did they install your alternator? Was this someone you knew?

Dropbox works (right?), but I guess the img img tags don't like https.

The shop I used is a local repair shop that's been here for 30 years.
They quoted a flat fee of $120.00 before I took it in, and I agreed to that.
I bought the alternator (a rebuilt unit) at a local auto parts store, and just brought that with me.
When I picked up the truck the next day, the owner said the techie was heard cursing and swearing the entire time he worked on it.
I'm not surprised. I got my $120.00 worth for sure.
Six months after that, my starter crapped out.
I took the same route: bought a rebuilt starter and paid the same shop to replace it.
I think the same guy replaced it because the air was still blue in the shop when I picked up the truck...lol
That's not a fun job either.

I'm not familiar with dropbox. I use photobucket.
There's a "how to" sticky in General Chat that explains in better detail how to post pics.

[varnco]

So, I finally got the sucker out! I figured out why I couldn't get the connector to come off the alternator - the connector was melted to the connector on the alternator. I ended up pulling the entire section out of the alternator.

I don't think I have the tools/skills/space to fix a melted connector, so I'm probably going to have to get this thing towed to a repair shop and have them fix the connector and go ahead and install the alternator. Do most shops install your equipment (Alternator)?

So, in case any pscho wants to go ahead and change their alternator, here's my instructions. I would strongly advise you to just get it done elsewhere:

1. Remove fan shroud.
It's in 2 sections, lower section clips apart (be gentle, they'll break on you) and pull it down and out.
The top section, there are 2 bolts holding it to the radiator and 2 bolts holding some cable (throttle?). Remove all 4 bolts and then slide and mess with it a little pulling on each side a bit up... it's tight, and pull the shroud up and out.

2.Remove alternator bolts
Remove bolts from alternator, there are only 2 holding it in place. There is a square nut on a bracket that goes n the back of one of the bolts (I believe the top/long one)... don't lose it, you'll need it when installing the new alternator. One bolt is short, the other is quite long.

3. Remove 3 wires from alternator
Use a socket and remove nut that is under the rubber protector at the end of the thicker cable. I did this from the top.
Use a socket and remove the bolt that holds the skinnier wire. I did this from underneath, using a long extension with swivel end.
Push in one side of the connector (the side you can't see) and pull on the connector. It should come up, unless it's melted like mine was. If you find this won't come out, go to step 4 and remove the bracket/conduit and you'll get a lot more room to get in there and see what you're doing. #4 is limiting the movement of your alternator at this point.

4. Remove Wire bracket/conduit that is nutted to the back of the alternator
10mm size nut. I used a small, ratcheting wrench and took my time and cursed a few times. You are doing this 100% blind and via feel only. The bracket that holds the wire comes off from the back of the alternator once the nut is removed.
For the life of me, I can't understand why they did this and why this isn't mentioned in the service manual.

5. It's free! Remove the alternator
You want to reach down from the top, and pull the alternator up, between the blades on your radiator fan. slowly rotate the blade while the alternator comes up between 2 blades.

I'm not going to do the install, so I assume the installation is the reverse. If I were doing it, I probably would not attach #4... I"d probably just leave it dangling. It's so tight... there's not much room for any movement.

AGAIN... i have replaced many alternators, starters in my lifetime and this was the absolute worst job ever. Just pay to get it done. Not worth doing it yourself.

[CzarinaRukhina]

My daughter and I replaced ours just about 3 months ago
It's exactly as you write..although we did the install as well. I'm a girl. And the alternator is not a light piece of machinery; it's very heavy and it's funny to read your post about working 'blind' at a certain stage - ah yes...hard on it's own but even harder while holding up the alernator.
Today I will be putting in a new radiator - yay! The coolant step has me worried a little because of air pockets, running engine, valves... Ugh

[RR425]

It's not that bad. Just removed the alternator on my 01 qx4 today. The key was to remove the battery to get to it from the top. Once you remove the battery and the two bolts that hold the alternator, getting to the bolts that hold the wires is easy.

I'll see how installation goes when I get my Denso alternator from amazon. The only problem could be getting the nut on the top bolt. But I bet it will be fine.

So far this has been easier than replacing the rear control arm bushings. And that wasn't all that difficult.