Alternator removal... from the top--long - Saab 9-5 Bulletin Board - Saabnet.com
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Alternator removal... from the top--long
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Posted by Paul E [Email] (more from Paul E) on Fri, 16 Apr 2010 09:42:37 Share Post by Email
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A few weeks back I had a second alternator begin announcing its eventual failure, with the usual grindy vibrating noise, thanks to bearings beginning to fail.

I had just had things apart a couple weeks previous, when I had to replace the power steering pump, so perhaps the spray of CHF-11 all over the engine compartment, or maybe the new serp belt stressed the alternator bearings... I don't know.

Anyway, the R&R procedure in the WIS says to remove the top motor mount, the belt tensioner, drop the exhaust, loosen the back engine mount and take it out from the bottom.

My jackstands are currently holding the 9-3 project car up (another story), I really didn't feel like going under the car with nobody else around, plus I really didn't even want to THINK about loosening the bolts holding the downpipe and cats to the middle section, as it's the original 250k mile exhaust system; my other option would have been to drop the entire system (I've done that before).

Instead, I managed to get the alternator out from up top with a little effort. I removed the top mount, the belt tensioner (to get at the bolt head, I used a 8mm bit--in my case, a T-50 bit reversed to the hex side-- and an 8mm box wrench with small pipe cheater), then the alternator (bottom bolt accessed from the inner fender with lots of extensions), leaving it down there for the moment. Next the aluminum bracket that holds the alternator in was removed, then I removed the nut holding the back engine mount.

Since I had a floor jack under the oil pan already, I lifted the engine up enough to easily wiggle out the alternator; MUCH easier than using a pry bar to nudge the engine enough to drop the alternator out.

Instead of another Bosch re-manned alternator, I took the unit to an auto electric shop, which went through the unit and put new bearings in; everything else was okay. They had it done three hours after dropping it off there, and for only $75!

Putting it back together took less than an hour. All good.

Paul
'01 Aero, 252k miles

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