djstepanich

Hi,

The regulator went in my 2002 C4 996 and I removed the alternator using the instructions at: http://p-car.com/996/diy/sai/mainpage.html..

The regualtor has been replaced and had a bearing replaced while out but now I'm having a heck of a time trying to get it back in. The area is very tight and can't get the right side of the alternator to line up with the bracket.

I'm wondering if anyone has any tips on how to get it back in and seated correctly? I didn't want to pry it into place too hard so any tips would be appreciated.

Do you need to bring the alternator down from the top of the bracket on the right side? Bottom up seems like a very tight fit.

Appreciate the help.

Darron

Ubermensch

I can't remember if I went from the top or bottom, but I believe it was top. The issue is that when you tighten down the alternator during installation it bends the mounting tabs in ever so slightly. Part of the removal instructions is to use the existing bolt to press those flanges back apart. In the end it will still take some prying, hammering and cussing. Good luck.

S.

redridge

yeah.... PIA, keep playing with.... I forgot how I did mine, but use some leverages when you can. You'll get it.

swmrdrn

I did it last month as well. A complete pain in the *** to get back in. I really don't know what I did to make it fit. After 15 minutes of swearing at it all of a sudden it dropped into place. I mean really, they couldn't have found an extra 1/4 inch to make R&R'ing the thing easy?

Pac996

I think the servide manual mention something about there is a twist you do while inserting it to the position.

djstepanich

Not room for much of a twist from my experience. Did you guys try getting it in from the top down or the bottom up on the right side?

Looks like it is a bit of an art

Any other tips would be appreciated to save some additional cursing.

Darron

Pac996

Try this "wooden mallet

http://www.6speedonline.com/forums/9...e-replace.html


This guy is just funny so I included him

http://www.youtube.com/watch?v=InFBp...ext=1&index=71

Chris996

I just had the Alt. out friday, it went in and out with no problem. Make sure the plastic air tubes are out of they way.

djstepanich

Thanks for the pointers. I think my bushing might not be released enough so might be makingit too tight to get back on the alternator bolt bracket. Some recommendations over on renntech pointed this out as I had a similar tight issue getting it out.

http://www.renntech.org/forums/index...tight-bracket/

Going to try tapping the bushing in a little more and see if that helps.

Thanks for the tips.

Pac996

Hey Chris996 that looks like what I was reading. Just can't recall where I found it or if I saved it to disk.

One thing not included in work shop manuals is where to leave the skin and blood of your fingers and knuckles. In some cases its just a parts of the job.

Tippy

Put the bolt in that goes through to a bushing and thread it in a little. Now, tap with a hammer until the bushing moves outward slightly.

The alternator will drop right in now.

djstepanich

sounds like my bushing may be sticking out too much and making it too tight. I did try giving it a few taps when pulling it out but maybe I didn't apply enough force. Now that it is out I'll give it a go and see if that helps.

Thanks for the tips. I should get to this on the weekend and will follow up with my experience.

Darron