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Alternator mounting bushing replacement... what NOT TO DO! 200

posted by  Jorrell on  Tue Jul 10 16:43 CST 2007
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last visit: Thu Dec 27 03:00 CST 2012
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Okay folks, hopefully you know I enjoy sharing positive results for repair/maint. jobs. Well, this one didn't have a good outcome as I took a shortcut... so BEWARE and LEARN!

While changing the oil, I realized that the accessory bushings on the alternator were shot... big time. I looked at the back of the alt, saw the rubber cover on the main positive cable mounting bolt and "thought to myself" heck, no need to disconnect the battery... after all, that aftermarket radio is a PITA to reprogram (required if the battery is disconnected).

So I decided to do the job without disconnecting the battery. Removed the upper tensioner, popped off the alt belts, removed the bottom long mounting bolt, pushed the alternator aside and BAM! Chunks of molten metal are flying here, there, and everywhere along with a steady flow of smoke and oil! I don't like to curse, but my first thought was "WTF?" especially considering I was laying under the car on my back!

I got out from under the car and managed to "rip" the negative battery cable off the battery... the fireworks show then quit... thank the Lord!

So, what happened??? Simple, when I remove the alternator from the lower mount, it slipped downward, caused the rubber cover on the power lead to fold, and the power stud on the back of the alt hit the oil filter! It burned a 1 inch long slot in the oil filter housing and I am just glad that the oil wasn't full of gas due to a running rich situation... otherwise, I wouldn't be writing this message!

Keep in mind that your typical car battery can source well over 7800 Watts of power for minutes on end when shorted! This is the first time that I have EVER taken this shortcut, but I can assure you I will never do it again!

I just hate it when my haste humbles me/makes me feel like an idiot, but hopefully, this message will save others from the same problem! If so, I'll feel it was "worth while" stupidity on my part!

jorrell (currently wearing dunce hat!)
--
92 245 250K miles, IPD'd to the hilt, 06 XC70, 00 Eclipse custom Turbo setup...currently taking names and kicking reputations!






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