Need Help Removing Alternator
Thread Starter
Racer
Joined: Jun 2011
Posts: 283
Likes: 5
Need Help Removing Alternator
Hi everyone. I just ordered the FSM for my 1996 coupe auto. However I need to remove the alternator. I"LL try to describe it as best as possible. First, what is the exact order in removing it. This is what I've so far. From the driver's side, I removed the long bolt and the positive wire on top. There's torx screw on the top but it won,t loosen and now it's stripped. I've tried to use locking pliers but it won't budge. I still have the belt on. Do I have to take off the belt first? Also, are there any more bolts or connections underneath? If I have to take the belt off first, would the stripped bolt come off easier? One last thing, what can I do to get the stripped bolt off. Thanks in advance, Ed. Also, this forum is great to use for help.
Last edited by Dr_Shakalu; Apr 2, 2012 at 01:06 PM. Reason: wrong part
Le Mans Master
Joined: Mar 2001
Posts: 7,999
Likes: 14
From: Life is just one big track event. Everything before and after is prep and warm-up and cool-down laps
Cruise-In III Veteran
Cruise-In IV Veteran
St. Jude Donor '12
Belt needs to come off.
Then the braces, IIRC there are two of them. One to the exhaust and one to the intake.
On my 92 its one bolt at the intake, one on the alternator and one on the AC compressor.
Then its two star head bolts holding the alternator on.
Then you can remove the red wire and the harness connector.
For your bad bolt head, its going to be interesting - try one size smaller socket that you can destroy, hammer it on and use a long handle breaker bar.
Then the braces, IIRC there are two of them. One to the exhaust and one to the intake.
On my 92 its one bolt at the intake, one on the alternator and one on the AC compressor.
Then its two star head bolts holding the alternator on.
Then you can remove the red wire and the harness connector.
For your bad bolt head, its going to be interesting - try one size smaller socket that you can destroy, hammer it on and use a long handle breaker bar.
Thread Starter
Racer
Joined: Jun 2011
Posts: 283
Likes: 5
If you're talking about hammering in socket to the bolt head that wouldn't work because the bolt head is round. I was thinking about taking a larger size Allen wrench and hammering it in or take the closest size Allen wrench and use JB Weld to connect the wrench to the stripped head
Belt needs to come off.
Then the braces, IIRC there are two of them. One to the exhaust and one to the intake.
On my 92 its one bolt at the intake, one on the alternator and one on the AC compressor.
Then its two star head bolts holding the alternator on.
Then you can remove the red wire and the harness connector.
For your bad bolt head, its going to be interesting - try one size smaller socket that you can destroy, hammer it on and use a long handle breaker bar.
Then the braces, IIRC there are two of them. One to the exhaust and one to the intake.
On my 92 its one bolt at the intake, one on the alternator and one on the AC compressor.
Then its two star head bolts holding the alternator on.
Then you can remove the red wire and the harness connector.
For your bad bolt head, its going to be interesting - try one size smaller socket that you can destroy, hammer it on and use a long handle breaker bar.
Burning Brakes
Joined: Dec 2008
Posts: 1,021
Likes: 7
From: Morgan Hill and Marina California
EZout on the stripped bolt. Torx is good for this because the Torx
will center the drill. Get GOOD new drill bits for this job. And get a new.
drill smaller than the final size first by about half. That will make the
bigger drill go in quickly.
Apply PBblaster a couple of times a day for several days first.
There are some reverse direction drill bits. It might be worth getting
one for the bigger drill, it certainly won't hurt and might pop it loose
while drilling.
The alternator housing is Aluminum. A torch applied after you drill
and just before you put the EZout in would help. Aluminum has a
higher coefficient of expansion than steel, so that might loosen things
up.
I hate it when this happens. I was changing out the thermostat
on a '68 Firebird 400 ragtop automatic with A/C. The bolt came out
when the front cover broke. Well, there were maybe 500 '68
Firebird 400 ragtop automatic with A/C, and they had a unique front
cover. Fortunately, this was about 1983, and GM still had a few.
One final thing: Permatex antiseize on the threads when they go back
in. All bolts into aluminum should get this. It doesn't hurt in steel
either.
Chuck
will center the drill. Get GOOD new drill bits for this job. And get a new.
drill smaller than the final size first by about half. That will make the
bigger drill go in quickly.
Apply PBblaster a couple of times a day for several days first.
There are some reverse direction drill bits. It might be worth getting
one for the bigger drill, it certainly won't hurt and might pop it loose
while drilling.
The alternator housing is Aluminum. A torch applied after you drill
and just before you put the EZout in would help. Aluminum has a
higher coefficient of expansion than steel, so that might loosen things
up.
I hate it when this happens. I was changing out the thermostat
on a '68 Firebird 400 ragtop automatic with A/C. The bolt came out
when the front cover broke. Well, there were maybe 500 '68
Firebird 400 ragtop automatic with A/C, and they had a unique front
cover. Fortunately, this was about 1983, and GM still had a few.
One final thing: Permatex antiseize on the threads when they go back
in. All bolts into aluminum should get this. It doesn't hurt in steel
either.
Chuck
Le Mans Master
Joined: Jan 2006
Posts: 6,564
Likes: 6
From: Woodstock Georgia
First off discount a battery cable at the battery before you do anything else.
The two round headed bolts on the alternator are torx head, not allen head. Get the right wrench and try again. But take the belt off first.
Be carefull in disconnecting the wiring harness on the back side of the alternator.
The two round headed bolts on the alternator are torx head, not allen head. Get the right wrench and try again. But take the belt off first.
Be carefull in disconnecting the wiring harness on the back side of the alternator.
Thread Starter
Racer
Joined: Jun 2011
Posts: 283
Likes: 5
I tried a torx wrench but the largest size I could find was a T40 which is also the same size for bolts to my targa top. What size and where can I get it?
First off discount a battery cable at the battery before you do anything else.
The two round headed bolts on the alternator are torx head, not allen head. Get the right wrench and try again. But take the belt off first.
Be carefull in disconnecting the wiring harness on the back side of the alternator.
The two round headed bolts on the alternator are torx head, not allen head. Get the right wrench and try again. But take the belt off first.
Be carefull in disconnecting the wiring harness on the back side of the alternator.
