2002 Alternator Rebuild
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
2002 Alternator Rebuild
Newbie to the C5 section here. 
I came to you guys because I am in the beginning phases of my LS1 transplant to my 70 vette. I have removed all of the accessories on the front of my new LS motor and want to start cleaning them. I figured I would start with the alternator. I want to remove the casing and bead blast it. I have all the screws removed and I am unable to separate the halves because the field is soldered to the diode trio. It appears that I should be able to use my soldering gun to remove this solder. But for the life of me, I cannot get it to melt. Anyone have any ideas on how to separate the halves.
Any suggestions or help is greatly appreciated.
I came to you guys because I am in the beginning phases of my LS1 transplant to my 70 vette. I have removed all of the accessories on the front of my new LS motor and want to start cleaning them. I figured I would start with the alternator. I want to remove the casing and bead blast it. I have all the screws removed and I am unable to separate the halves because the field is soldered to the diode trio. It appears that I should be able to use my soldering gun to remove this solder. But for the life of me, I cannot get it to melt. Anyone have any ideas on how to separate the halves.
Any suggestions or help is greatly appreciated.
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St. Jude Donor '06-'07-'08-'09-'10-'11-'12
The leads are welded to the diodes if it is a newer model alternator. What is the part number on it? Sometimes they'll pop off, sometimes they won't. When I disassemble and chrome the alternator I will replace the diodes. You have to press them out and press new ones in. When getting them loose from the regulator it is easiest to cut them. Once they are pressed back in you need to clean up the leads (carefully) on the regulator so you can solder the new ones on.
Team Owner
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From: S.W. Ohio. . . . . . NRA Life Member
I took apart my 2002 alternator. The windings are connected via high-temp solder. A good soldering gun will loosen the connections if you take your time.
read here:
http://forums.corvetteforum.com/show....php?t=1608707
read here:
http://forums.corvetteforum.com/show....php?t=1608707
Thread Starter
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
I looked and could not find a part number on the alternator. I am guessing it may be under the rectifier/diodes. Here is a pic of the connections I am talking about. BTW, the alternator is off of a 2002 LS1 from an SS Camaro.
These are the connections that I need to get apart, correct.
These are the connections that I need to get apart, correct.
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From: Now in God's Country, the Big Sky, Montana!
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St. Jude Donor '06-'07-'08-'09-'10-'11-'12
Those are the main leads like the alt Mike posted above. Just get a decent soldering gun. Those will come off with no problem. The ones I am talking about are on the newer alternator (the only one available from GM for all year Corvettes now). This one is a easy compared to the new ones. It is thick solder and takes a little heating. Heat it up and when you see the solder "wave" you can then take it loose.
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From: Lenoir City Tennessee
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St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
I will get after it again tonight when I get back home from the corvette club meeting. 
When it waves at me, I will wave right back at it, then pull its little arms off. 
When it waves at me, I will wave right back at it, then pull its little arms off.
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Thread Starter
Race Director
Joined: Feb 1999
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
Okay I finally got a chance to get after the alternator again today. I got the connections apart. Now for some reason, I still cannot get the alternator halves to come apart. I pried on the halves with a screwdriver but got nowhere. So, I figured I would come back and ask again.
These do not come apart like the OEM stuff of 1970.
These do not come apart like the OEM stuff of 1970.
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From: Now in God's Country, the Big Sky, Montana!
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St. Jude Donor '06-'07-'08-'09-'10-'11-'12
That is one funky **** lookin' alternator. Did you take the car muddin'? 
It should come apart after you take the bolts out. Pry on it some more. That black piece on top should come off as well. At least it does on the later model alts, I haven't taken one like this apart yet.
Did you take the car muddin'? It should come apart after you take the bolts out. Pry on it some more. That black piece on top should come off as well. At least it does on the later model alts, I haven't taken one like this apart yet.
Thread Starter
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
That is one funky **** lookin' alternator. Did you take the car muddin'? It should come apart after you take the bolts out. Pry on it some more. That black piece on top should come off as well. At least it does on the later model alts, I haven't taken one like this apart yet.
Did you take the car muddin'? It should come apart after you take the bolts out. Pry on it some more. That black piece on top should come off as well. At least it does on the later model alts, I haven't taken one like this apart yet.Last edited by Eddie 70; May 2, 2007 at 11:08 PM.
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From: Now in God's Country, the Big Sky, Montana!
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St. Jude Donor '06-'07-'08-'09-'10-'11-'12
Ahhhhh, you know that will make your car go slower right? I would check into it a little more before you get too deep into it. Earlier model cars seemed to have problems with the charging system when using non specific alternators. You used to have to buy year specific ones up until not too long ago. Now, there is only one part number for 97-04 cars.
Thread Starter
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
It is a whole Camaro SS motor. This is going to be my winter project this year. Drop the LS into my 70. I was wanting to try and clean all the brackets and accessories up.
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From: Now in God's Country, the Big Sky, Montana!
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St. Jude Donor '06-'07-'08-'09-'10-'11-'12
Gotcha, good Lord, it looks like that alt would be a pain to get to with the engine in the car.
Thread Starter
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
Now you know the reason I want it to be all cleaned up and working correctly before I drop it back in. If I could just get the sumbeach apart I would be on my way with the alternator. I will get it eventually.
Thread Starter
Race Director
Joined: Feb 1999
Posts: 19,659
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From: Lenoir City Tennessee
Ci 6, 8 & 10 Veteran
St. Jude Donor '05-'06-'07-'08-'09-'10-'11-'12-'13-'14-'15
I made a little progress using two screwdrivers on opposite sides of the casing. Now to get the rotor out. It seems to be fused to the front bearing.
