difficulty removing alternator '96 4.9l e-150
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difficulty removing alternator '96 4.9l e-150
helo, my simple alternator removal has not been simple. i'm stuck right now and here's the description.
i've removed the 2 mounting bolts to the alternator, removed the belt and disconected the the electrical connections to the alternator. i hav also removed the odd cluster ontop of the alternator, which was a diverter/bypass valve combo thing. so now the alternator is totally disconnected and can be spun around any which way but i cannot lift it out. the large half moon mounting bracket blocks it from be removed up down or forward. the engine blocks it to the rear and driverside while the large black plastic box housing ac and heater fan/stuff blocks it to the passengerside.
my guess is to remove the mounting bracket via 2 bolts going into the engine block and some how deal with whatever pump is mounted to the bottom of the bracket below the alternator. is this the correct course of action? i would love some advice here. thankyu much.
i've removed the 2 mounting bolts to the alternator, removed the belt and disconected the the electrical connections to the alternator. i hav also removed the odd cluster ontop of the alternator, which was a diverter/bypass valve combo thing. so now the alternator is totally disconnected and can be spun around any which way but i cannot lift it out. the large half moon mounting bracket blocks it from be removed up down or forward. the engine blocks it to the rear and driverside while the large black plastic box housing ac and heater fan/stuff blocks it to the passengerside.
my guess is to remove the mounting bracket via 2 bolts going into the engine block and some how deal with whatever pump is mounted to the bottom of the bracket below the alternator. is this the correct course of action? i would love some advice here. thankyu much.
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the alternator is up and loose. i can lift it, spin it and hav any side i want facing up but i cannot arrange it in such a way to slip it past the half moon mount.
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i never excelled at the rubix cube but with a new sun tomoro i can giv it another try squeezing it thru there. maybe i can push the side of the ac/heater in a bit and get some wiggle room?
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Sorry I can't give you more specifics. When I did mine I got up early trying to get it done before work, took forever to get the long bolt out, when i got it loose and couldn't get it out I was like WTF. Then found out I had the larger alt not the small one that I already bought.
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that was horrible but alternator is removed. in the end the trick was to unbolt and slide over the plastic guard from the radiator, lift the alternator so the pulley side faced the rear of the vehicle. then get it wedged between the radiator and the mounting bracket. once there i used a flat head screwdriver between the radiator and alternator and gave it a slight pry while rolling and lifting the alternator. not force but prying while rolling it out of there. after doing that a few times it came free.
now to find a replacement that is much smaller but has the same mounts and to repair all the vacuum hoses i broke. ugly.
i did open up the ac/heater box and there really wasn't much give there because filling that box is a metal radiator type thing.
i'm open to any replacement alternator suggestions if anyone has one.
now to find a replacement that is much smaller but has the same mounts and to repair all the vacuum hoses i broke. ugly.
i did open up the ac/heater box and there really wasn't much give there because filling that box is a metal radiator type thing.
i'm open to any replacement alternator suggestions if anyone has one.
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i feel its only appropriate to add the final outcome when i can.
the way to get the alternator free was to detach the plastic extension on the back of the radiator then to remove the 4 bolts holding the radiator in position. then slide both items over a bit and then there is room to rotate and remove the alternator. it was quite easy to move the radiator over a bit and i did not disconnect any of its piping and thus did not need to drain it and such.
the way to get the alternator free was to detach the plastic extension on the back of the radiator then to remove the 4 bolts holding the radiator in position. then slide both items over a bit and then there is room to rotate and remove the alternator. it was quite easy to move the radiator over a bit and i did not disconnect any of its piping and thus did not need to drain it and such.
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A better way
Just had the same difficulty on 1992 e-150 4.9 130 amp alternator. I had to remove the fan and fan shroud - easy with free tool from local autostore. I unscrewed tensioner assembly and there was just barely enough space to very carefully take it out and put a new 130 alternator in.
5th Wheeling
Joined: Apr 2013
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On my 1993 e-150 4.9, I must remove the radiator to replace the alternator. The lower alternator bolt hits the radiator 
I replaced the radiator just recently and now I have to remove it again to replace the alternator. Yay.
I replaced the radiator just recently and now I have to remove it again to replace the alternator. Yay.
Lead Driver
Joined: May 2004
Posts: 5,017
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From: Maryville
Most have a sleeve that self adjusts it as you tighten, that makes it hard to get out, drive the sleeve back to give room to pull it out, plan to put a 3G on my 89 sometime this year.
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