Engine/Transmission (1998.5 - 2002) What the @#$%!!!!

[Curious Dave]

So... I am working on the truck and looking around at my hadiwork and seeing what else I might need to spruce 'er up. The alternator catches my eye.

The tension on the serp belt and the vibrations have managed to team up and cause the alternator to machine itself a slot in the alternator adjustment bolt hole built into the case.

Has anyone else seen this?

Can I wled the case w/o taking the alternator apart?

Will the internals handle it? i. e. The diodes?

The alternator works fine. I have no idea how long it has been like this. I thought about leaving it... but i am concerned that it may break the bottom mount and the belt may swing it around like a mace. Any thoughts?

 

[aircop]

You could try welding it. I think I would just pick up a new alternator.

 

[Curious Dave]

I am picking one up today... I am also wondering if I should drill it out and put a steel sleeve in the hole to eliminate this from happening again.

 

[BigPapa]

May be the difference in year models or in who actually manufactured the part, but mine is different from yours. Mine is solid where I've drawn the red lines. I'd bet yours is made with that slot in it, maybe to aid in installation. Can't really tell from the pics but is the edge of the groove rough like it broke? I don't see any way that that much material could have just worn away.



Scott

 

[jkidd]

same thing happened to me at about 150k. The softer metal in the alternator housing let the bolt cut through it like butter over time. the roughness is the threads of the bolt. Alternator was still good, but just replaced it. went to partsamerica . com it is kragens wholesale site and I got it for $60 less delivered.

not sure of any good fixes. I was at the inlaws and decided with lack of tools and age of alternator that I would just get a new one.

 

[tom sweeney]

CD... my '01 did the exact same thing,i replaced it with a new alt..... good luck... . tom

 

[BigPapa]

Well, that answers that.



Scott

 

[odieub]

Thought I Was The Only One My 01 Was Like That Wen I Bought It

208k I Could Not Aford The New Alt At The Time $200 So I Got A Real Good Bolt And Really Senched Her Down Worked Great For About 7k Then Alt. Took A Dump. So Got New Alt.

 

[tom sweeney]

... . i assumed metal fatigue... still had enough tension to charge system though!!... ..... tom

 

[Curious Dave]

Well... Mine is still charging. But I went ahead and bought another one. Maybe I'll get it welded and hang onto it. Sure is interesting that the '01 seems to be the common year.

Where are the other years alternators mounted in relation to belt direction. I mean this is mounted @ 11:00 w/ counterclockwise rotation. Are the others similar?

 

[LBARTLETT]

Im checking mine tomorrow, i have 175k

 

[Curious Dave]

Okay... I went and bought a remaned with a lifetime warranty. I get it to the truck and decided to put a sleeve in the top ear so this won't happen again. I found a piece of SS tubing I have had around for awhile and I cut a piece off. I then found my 1/2" drill bit and punched the hole oversize. I didn't go all the way thru just so the sleeve would only go in from the front. The hardened steel bolt is worn 1/2 way thru also... But a new bolt and I will be back in business. I also put on a new belt. Good time to do it too.

 

[DavidC]

Although you have probably solved your mechanical problem it could cost you the lifetime warranty. On the other hand if you need to replace it the manufacturer may see this as a good idea and incorporate it in future productions:-laf. I know that the early Chrysler products used steel sleeves for the aluminum alternator housings.



Dave

 

[Curious Dave]

I thought about the whole warranty thing... But after managing a CSK for awhile and seeing some of the things the counter jockeys do... well... I don't think they are going to notice . 020" missing from the hole.