Jump to content

Welcome to RennTech.org Community, Guest

There are many great features available to you once you register at RennTech.org
You are free to view posts here, but you must log in to reply to existing posts, or to start your own new topic. Like most online communities, there are costs involved to maintain a site like this - so we encourage our members to donate. All donations go to the costs operating and maintaining this site. We prefer that guests take part in our community and we offer a lot in return to those willing to join our corner of the Porsche world. This site is 99 percent member supported (less than 1 percent comes from advertising) - so please consider an annual donation to keep this site running.

Here are some of the features available - once you register at RennTech.org

  • View Classified Ads
  • DIY Tutorials
  • Porsche TSB Listings (limited)
  • VIN Decoder
  • Special Offers
  • OBD II P-Codes
  • Paint Codes
  • Registry
  • Videos System
  • View Reviews
  • and get rid of this welcome message

It takes just a few minutes to register, and it's FREE

Contributing Members also get these additional benefits:
(you become a Contributing Member by donating money to the operation of this site)

  • No ads - advertisements are removed
  • Access the Contributors Only Forum
  • Contributing Members Only Downloads
  • Send attachments with PMs
  • All image/file storage limits are substantially increased for all Contributing Members
  • Option Codes Lookup
  • VIN Option Lookups (limited)
Silver_TT

Trying to remove 996 alternator but it's stuck

Recommended Posts

Got to the alternator this evening pretty quickly en route to switching out the voltage regulator in the alternator. On the left side of the alternator where a single bolt holds it in, I can get some play moving the alternator up/down....Only problem is the right side of the alternator, the side with the screw that goes throught the pulley, (see red circled area in attached pic) won't budge. I think it's just pinched on there real tight after the last 10 years, as that screw goes through the pulley and the flange and screws in near the back of the alternator. I tried giving it some taps with the hammer but it's at an ackward angle and I'm not getting much traction. The thing is either stuck or I need to start hitting the gym more often, one of the two.

Anything obvious I'm missing with respect getting the alternator in/out? It's right at the front of the motor--shouldn't be this hard. I'm hoping it's not this hard getting it back in there too once I'm finished with the alternator repair.

Thanks in advance for any thoughts or comments.

post-72654-0-08860200-1342580861_thumb.j

Edited by ferrugia

Share this post


Link to post
Share on other sites
    You can remove these ads by becoming a Contributing Member.

Thanks for the response, Loren. I did previously see that support topic post regarding your DIY. It looks like some other people have had similar issues. Unfortunately, in my case, the alternator is "stuck" on the right-hand side and so I'm not really able to pry it out of there.

If anyone has any brilliant ideas I'm all ears -- else I will try to use a crowbar tonight and use more force (while trying not to damage the alternator/fins). I might spray some WD-40 on that right side once it's out to make it easier to get back in after I replace the voltage regulator.

Good times, good times.....

Share this post


Link to post
Share on other sites

There is a small threaded bushing in the rear mounting flange of the alternator that moves slightly forward when the bolt is tightened, clamping down on the bracket. If you thread a bolt into that side (item #7 in Loren's DIY), leaving it loose, and then tap the bolt with a dead blow hammer, the bushing will release the mount and the alternator can be removed (after removing the bolt). You can see the bushing in this photo on the rear "ear" of the alternator, near the Bosch box:

altbox.jpg

Edited by JFP in PA
  • Upvote 1

Share this post


Link to post
Share on other sites

Thanks JFP, you were right (of course).

For people doing this in the future: Follow the instructions in Loren's DIY very carefully (don't be dense like me). The instructions explicitly say in step 7, "Undo right fastening screw (with deflection roller) by three turns. A gentle tap on the fastening screw loosens the threaded bushing in the generator arm (use aluminum mandrel)."

I made the mistake of completely unscrewing and taking out the long bolt right off the bat -- Wrong! Should have followed instructions. It makes a lot more sense now that I understand how the bushing pulls forward in the rear flange. Trying to get the bolt back in proved to be an arduous task. Aligning the alternator was quite difficult. Be very careful not to strip the bolt. Lots of swear words may have been spoken in my garage last night :)

The irony of this DIY was that getting into the engine and accessing the alternator was trivial. It only took under 10 minutes if you don't count my trip to the hardware store to get a set that contained 14mm, 15mm, and 24mm sockets. Conceptually, replacing the voltage regulator is very, very easy. However, in practice, in my case anyway, getting the alternator actually out to do the replacement once I got to it was a major PITA. I can tell that getting it back in tonight is going to be a lot of fun too.

Thanks again JFP for your guidance in helping me with this. Next round of beers is on me :cheers:

Edited by ferrugia

Share this post


Link to post
Share on other sites

Apologies for resurrecting a dead thread, but I am too am stuck on the alternator bushing part.

 

When it's stated the bushing moved forward, does that mean towards the front of the car?  How do you know when the bushing has moved far enough?  Will it be flush with the alternator?

 

Reading the DIYs I knew I was in for a struggle.  Each night this week I soaked the bushing in PBlaster.  After hammering on it for a couple hours and applying more PBlaster, I'm not sure it's budged at all.  With the bolts removed, both the left and right sides rotate clockwise a bit, but don't drop or otherwise move. 

 

Any further suggestions or do I just keep at it?

Share this post


Link to post
Share on other sites

I would say you are going to have to keep at it.  Do exactly what the instructions say to do...back the long bolt out 3 turns and whack the bolt head hard.  Harder than you think.  The rear bushing has to move in order to create the space needed to remove the alternator.  I put a towel on the car to protect it and used a brass boat prop shaft.  Lined it up on the bolt head with the end of the prop shaft outside the engine bay and hit it with a sledge hammer.  Don't overdue it because you can break the rear mount.  It takes just the right amount.

Share this post


Link to post
Share on other sites

Thanks Joe.  A couple hours with a 4lb dead blow hammer and a two foot piece of metal and it still hasn't budged.  

 

What's my tip off when it actually has moved though?  Will the bushing sit flush with the alternator?

Share this post


Link to post
Share on other sites
15 minutes ago, Andrew911 said:

Thanks Joe.  A couple hours with a 4lb dead blow hammer and a two foot piece of metal and it still hasn't budged.  

 

What's my tip off when it actually has moved though?  Will the bushing sit flush with the alternator?

 

It takes more force than you might expect; the bushing has to move back or the alternator will not come out.

 

Good luck.

Share this post


Link to post
Share on other sites
Posted (edited)

The bushing only needs to move enough that you can rotate the alternator up and out.  It does not have to be pushed all the way into the rear mount arm.  It really only has to move enough that you  can lift up the right side of the alternator easily.  Once you have the alternator out you will see how it all works.  With the left bolt out, how easily can you rotate the alternator up?  Or can you not rotate it at all?

Edited by DBJoe996
  • Like 1

Share this post


Link to post
Share on other sites

Are you sure you have not already moved it enough for the alternator right side to come up? Pull right side bolt all the way out and see if you can lift the right side up and out.  It might be a little bit of a struggle but if it moves up you can get it out.  I remember I had to go back and forth a few times, bolt in and whack, bolt out and try to lift, bolt back in and whack even harder, bolt out and test lift again.

  • Like 1

Share this post


Link to post
Share on other sites
On 5/12/2019 at 8:15 AM, DBJoe996 said:

Are you sure you have not already moved it enough for the alternator right side to come up? Pull right side bolt all the way out and see if you can lift the right side up and out.  It might be a little bit of a struggle but if it moves up you can get it out.  I remember I had to go back and forth a few times, bolt in and whack, bolt out and try to lift, bolt back in and whack even harder, bolt out and test lift again.

 

This has been my hope for a while, but I don't think so.  I have lifted on the bolt and it doesn't budge a fraction of a millimeter.  I can feel the bushing up tight against the bracket with no apparent gap of any kind...I can't fit a fingernail between it.

 

If I pull out the left bolt I can rotate the alternator clockwise some so it appears to be loose, but just still attached via the bushing (?).  Counter-clockwise is no go.

Share this post


Link to post
Share on other sites

In total desperation, you may have to pry the alternator out.  Rotate it as far as possible clockwise, remove the long bolt and pulley, and try to jam a thick screwdriver or small pry bar underneath the alternator rear mount arm.  You might have to be creative with a block or piece of wood to get the leverage right.  Be very careful of the oil filler tube.  It can crack easily.

  • Like 1

Share this post


Link to post
Share on other sites
Posted (edited)
On 5/14/2019 at 7:20 AM, DBJoe996 said:

In total desperation, you may have to pry the alternator out.  Rotate it as far as possible clockwise, remove the long bolt and pulley, and try to jam a thick screwdriver or small pry bar underneath the alternator rear mount arm.  You might have to be creative with a block or piece of wood to get the leverage right.  Be very careful of the oil filler tube.  It can crack easily.

 

Thanks again Joe.  I actually did end up using a block of wood to dislodge it.  Didn't break anything on the alternator and surprisingly the plastic connector for the AOS is still intact (for now....ha!)  Getting it back in may be another nightmare.

 

Funny you mention the oil filler tube.  That is exactly why I'm removing the alternator.  The tube cracked when I removed the airbox to replace the engine mounts.  I'm currently stuck trying to get it back in.  I used oil on the new o-ring and fill tube, but it doesn't want to go back in easily.  Any tip on getting more leverage?  I can only get my left hand in there.

Edited by Andrew911

Share this post


Link to post
Share on other sites
Posted (edited)

I take it you got the alternator out.  Good job!  When I replaced my oil filler tube, it seemed to go right in.  A bit of a struggle to push it down snug, but I had no difficultly lining it up and pushing straight down on it.  Took a picture right before I put the bolts back in.   Yes, all left handed work.  Ugh....

 

IMG_0453.JPG

Edited by DBJoe996

Share this post


Link to post
Share on other sites
Posted (edited)

Oh, that's weird.  My reply got truncated somehow and a link for the AO S keyword got added.

 

I wrote:

 

"Thanks again Joe.  I actually did end up using a block of wood to dislodge it.  Didn't break anything on the alternator and surprisingly the plastic connector for the AO S is still intact (for now....ha!)  Getting it back in may be another nightmare."

 

I know appearances can be deceiving but it looks like you have a lot more space to work.  In my car I swear that metal hard line butts right up against the rear bolt.  Glad to see I'm doing things right though and just need to struggle with it a bit more.

 

BTW, did you get the revised filler tube?  If so, how has it held up?

Edited by Andrew911

Share this post


Link to post
Share on other sites

Yes, got the latest and greatest, and it is holding up very well.  Good to hear you got in there.

Share this post


Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.


×
×
  • Create New...

Important Information

We have placed cookies on your device to help make this website better. You can adjust your cookie settings, otherwise we'll assume you're okay to continue.