Editing Alternator (section)

== Alternator Re-build ==

Should your alternator bearing pack up and you don't want to buy a new one (£165) or exchange (£120-140) or repair (£40), then you can always fix it yourself.

Doing this may stop you from being able to exchange an alternator at a later date, if you have any worries stop now.


1. Remove the alternator from the car as described above, access can only be achieved through the wheel arch, with the drivers rear wheel removed. Good luck getting it out between the engine mount and the fuel filler pipes, stick with it!

2. Once you've got the alternator on the bench remove the 2 nuts and the 1 screw holding the plastic cover on and remove, then undo the 3 screws (a&b + c not shown!) holding the electrical parts on - remove sideway and slide out with the commutators attached.

[[Image:alternator1a.jpg|thumb|left|Click to make bigger]]
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3. Undo the 4 long bolts, I used a screw driver with a hex shaft and drove it round with a spanner.

4. Using a sturdy flat blade screw drive prise the 2 halves of the body apart. This takes time and you have to work methodically work round from one side to another.

[[Image:alternator2.jpg|thumb|left|Click to make bigger]]
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5. Using a 2 or 3 leg puller pull the bearing off the shaft. I used a small hollow nut to protect the plastic shroud on the shaft, so that the centre of the puller pushed against metal instead of plastic.

[[Image:alternator3.jpg|thumb|left|Click to make bigger]]
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6. Measure the bearing using a vernier. Mine was 35mmOD, 17mmID by 10mm -- SKF 6003.
Go here

Enter you bearing dimensions and obtain a product code. Then take that code over to eBay and see if you can find a 99p replacement!
You could go for an uprated high temperature bearing but make sure the rpm rating is up to the job.

7. Refit the new bearing by either using a deep socket and drift or make a press from a jack, some wood and wedge under something heavy.

8. Align the 2 halves of the alternator and refit the 4 long bolts, tighten each one a 1/4 turn until tight. Refit the electronics in the reverse of disassemble, making sure to push the commutator back in first.

[[Image:alternator4.jpg|thumb|left|Click to make bigger]]
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EDIT by Dobbo.  There is another bearing at the pulley end.  No sense in just doing one whilst it's off the car and in bits.  The pulley nut is 24mm.  You'll need an impact wrench to undo it, or find a way to clamp it in a vice without damaging the pulley.  I used several layers of very heavy duty tape and clamping it very tightly.  There's also 4 screws to undo.  Once the nut is off, there's a washer and you'll need to drift the rotor out of the bearing.  Take care not to drop it when if comes free.  The bearing remains in the alternator chassis and will also need drifting out.  I used the same 24mm socket that I used for the pulley nut.


9. Refit to the car, reconnect the wiring and tension the belt as above.


Alternator parts supplier
http://www.woodauto.com/Unit.aspx?Man=BOSCH&Ref=0124225011