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Old 07-12-2014, 02:02 PM   #1
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Alternators suck

So about a month ago the alternator on my ng900 vert. I finally picked up a replacement a couple weeks ago. And attempted to install it last weekend. The bottom Allen head bolt is extremely corroded and the head was rusted. Long story short I can't get it out.

Is there a solution other than pulling everything apart and unbolting the mount from the block?

I'd really prefer not having to pull the axle and drop the subframe to get the whole assembly out of there.
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Old 07-12-2014, 05:42 PM   #2
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I've been know to cut bad alternators off! Wonder if you could destroy the old to get it out, then turn the bolt with a pair of vise grips in the area it spans the bracket.

My favorite tool is an air chisel for just this sort of thing.

Good luck!
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Old 07-12-2014, 05:47 PM   #3
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I was hoping to be able to get at it with a small air powered sawzall but it's a little too tight. I hadn't thought about using an air chisel. Maybe I'll try that tomorrow. Thanks for the idea.
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Old 07-15-2014, 09:23 AM   #4
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The air chisel did the trick. Not the easiest to accomplish in the space provided, but doable. Now I just need to finish taking the lower bolt out and get the replacement up in place.

Thanks for the great solution Tboy!
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Old 07-15-2014, 09:22 PM   #5
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nice
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Old 07-15-2014, 10:07 PM   #6
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The air chisel did the trick. Not the easiest to accomplish in the space provided, but doable. Now I just need to finish taking the lower bolt out and get the replacement up in place.

Thanks for the great solution Tboy!
I hope that you do not have a core on that unit! I am not sure they would accept that hahaha. .

Glad that you got it out... Very interesting approach to the situation! I need to cut more things lol.
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Old 07-16-2014, 07:16 AM   #7
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+1 Nice work.
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Old 07-16-2014, 11:01 AM   #8
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I call it getting mid-evil!!

Good job!

Air chisel or air hammer is seriously one of my favorite tools. I have a variety of blunt points as well for separating suspension components or removing rusty bolts from rusty bores. Ever mash the threads of a bolt trying to hammer it out? Air hammer baby, comes out perfect.

Last edited by Tboy; 07-16-2014 at 11:03 AM.
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Old 07-16-2014, 02:47 PM   #9
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Nice work. And yeah, air hammers are usually just the sunofabitch you need to get the job done!
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Old 07-17-2014, 03:54 AM   #10
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I hope that you do not have a core on that unit! I am not sure they would accept that hahaha. .

Glad that you got it out... Very interesting approach to the situation! I need to cut more things lol.
nope, no core. I was cheap and bought a used bosch alternator. I didn't want to spend $250 on a new one.

Last edited by turbojohnny; 07-17-2014 at 03:59 AM.
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Old 07-17-2014, 06:08 PM   #11
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get it back together yet
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Old 07-17-2014, 08:00 PM   #12
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Just got back from taking it out for a test drive. The new alternator is charging flawlessly. But that stupid water pump seems to be leaking even more now.
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