Alternator Braket - Heads Up

[glav]

Read in one of the later TDRs about a TSB on alternator brakets being cracked. Well after reading that I check mine and yes the stamped piece of 1/4" iron plate was cracked. Checked with Dodge and the part is not covered under warranty. And don't have the extended warranty and I am over the mileage now. The cast iron part was $85, ouch! So got out my 03 Service Manual and it told how to replace the bracket. So no big deal, just a couple of hours work and save a $100 doing it myself.



Well there are a couple of things the Service Manual didn't tell about. It is much easier to do if you take the air box out. Gives you more room. The braket is a very tight fit. Very easy to get mis-aligned, so had a problem with the install. The alternator uses two long bolts for mounting. There are two strange nuts with tapered shafts on them that mate up with the long bolts.

I had a real problem trying the get the alternator on the new braket, the fit was just too tight. I then took the alternator off and put the bolts in and hit it once with a small hammer to back the nuts out with tapered shafts. Then the alternator fit up nicely and when you tourgue the bolts it draws the braket tight againt the bosses on the alternator. The Service book says nothing about this. So jut thought I would let the group know.



Now to change out the Power Steering Pump Reservior, it is leaking!

73s

 

[sawmillman]

Leaking power steering tank

I have been successful removing the fluid from the reservoir with a turkey baster and then putting a two part mixer over the leak from the outside. The stuff I used was called Barco Bond. Not sure where to buy it now a days but there are products out there to try. Worth trying before removing the unit. Gene

 

[glav]

Thanks sawmillman for the tip on Barco Bond.

Gene

 

[ECappleman]

How do you tell which one you have? Is it the upper one that mounts on the side?

Mine is a bright silver with an indention on the top. I can see a few letters stamped on the inside near the inner rear bolts.

 

[SRadke]

The top bracket is what will crack. The old version is stamped from a piece of steel and will be realtily smooth on top. The new piece is cast iron and it has a pocket on top that you could pool a small amount of liquid in. Don't ask how I know about the liquid

 

[SRadke]

You can kinda see the new cast bracket in the forground of this picture. I've since removed it and powder coated the same color as my twin piping.

#ad

 

[ECappleman]

I see a turbo system I want!

But it is hard to see the upper bracket.



Found a pic in another thread. Mine must be the old style, because it looks like this one, but nice and shinny. Do they all crack at the bend like this one?

Alternator bracket



I'm out of the BTB warranty though.

 

[SRadke]

Yes the picture in the link is the older style. They'll crack at the bend just like in the picture and often from both sides. Even if you're out of warrantee I sugest questioning the dealer about it, they may be in a good mood and cover it for you. I also believe it will be covered under the 100k mile warrantee of the engine.

 

[ROCKJEEP]

Mine was cracked also, but I replaced it with kilby's on board air bracket.

Kory

 

[DPKetchum]

The bracket is OLD news. Very OLD TSB. (one of the FIRST if not the VERY first to come out when the 3g's were introduced)Had mine replaced when truck was new. Only took tech about 15 minutes.

 

[ECappleman]

The bracket is OLD news. Very OLD TSB. (one of the FIRST if not the VERY first to come out when the 3g's were introduced)Had mine replaced when truck was new. Only took tech about 15 minutes.

Maybe so, but some of us bought used 03's and didn't know about it.

 

[JHardwick]

Now to change out the Power Steering Pump Reservior, it is leaking!

Check the "O" ring where the reservoir enters the pump housing.

 

[DPKetchum]

The only way I was aware of it was by reading TSB's. Still do every now and then to see whats come out. Some dealers may baulk at doing that tsb as a good will gesture(being a KNOWN problem)but I know of some that it was handled at 100k no charge. But ON used and the age of these that may be a issue now. A REP I talked to over a year ago stated he expected HIS dealers to take care of that bracket as a GOODWILL out of warranty repair(its covered 3/36) But USED and age may change that aspect. No harm to ask or call D. C. (18009921997)and inquire.

 

[glav]

Got'er Done!

Below is a picture of the bracket with the scewdriver in the crack for clarification. Forgot to get a picture of the new one, but you are right it is made of cast iron. Not sure how to post a picture within this reply. But I think that I have attached it OK, but#ad

 

[ECappleman]

Called the dealer today.

3yr/36k only

 

[DPKetchum]

Of course he said that BUT I know of ones replaced at or near the 100k mark as a GOODWILL GESTURE which the service manager CAN do and a REP will not deny the claim as a KNOWN problem. As I stated earlier the rep in this part of Georgia said HE wanted HIS dealers to take care of it with a smile! Call up the food chain. 18009921997. Age MAY be a issue now. This was over a year ago I had this conversation with a rep at a D. C. store. They only used the stamp steele bracket a VERY SHORT time frame.

 

[ECappleman]

Called DC and they were very nice, but still said... ... . SORRY!

 

[DPKetchum]

To much time has passed. Oh well worth a try.

 

[ddutil]

I still don't understand why DC did not make a recall on this. Man, what if the bracket breaks at 70 mph - 2200 rpm ? I guess nobody has been wounded, yet... :-{} Dan

 

[MMeier]

I still don't understand why DC did not make a recall on this. Dan

Same reason they don't do a lot of things..... it will cost them $$$$$$$$$$$