Alternator Removal Help,,,,,,,

[PembsPanther]

Evening All :)

 

Battery light came on today totally out of the blue, no flickering nothing just on and stayed on, got home and dusted off the multi-meter the battery itself had just over 12 volts in it yet running the alternator was only outputting 11.63 so presume alternator knackered, ordered a good second hand one off Ebay being delivered tomorrow but could do with a bit of help fitting it, I have found the basic 7 or 8 step procedure but wanted to ask more about removing the auxiliary belt, where and how do I release the tension? Also I understand it is best to hold it up somehow to keep it on the bottom pulleys and advise on this?

 

Thanks in advance :)

 

[BrianH]

The 2.0 mk1 has an automatic tensioner - I believe the 2.3 is the same (guessing thats what your asking about as its whats shown on your profile). You just put a spanner onto the bolt head in the middle and push it to release tension (you don't need to undo it your just using it as a lever to hold the pressure). 15mm spanner from memory is whats needed.

 

I'd suggest you take some photos of the belt routing before you take it off - theres usually a few different ways it seems to fit, but isn't correct, and given the amount of pulleys involved it can take some time to work out the right route otherwise. You can just slip it off the alternator once the tension is released, but its unlikely to stay in place once you do.

 

You may find it useful to confirm its the alternator by giving it a sharp tap to see if the light goes out - it will only do so briefly (i got about 5 minutes from mine when it failed) but this should be enough to confirm that its that at fault - your description suggests so, though a good idea to check all the connections as well if you haven't before you start.

 

If you really want to hold it in place you might be able to use a length of string to the bonnet latch or similar anchor point, but it shouldn't be too much of a problem. You will need the undershield off to release the tensioner, and probably easier if you remove the wheel on that side as well.

[PembsPanther]

Hi Brian

 

Thanks for that, had a feeling it would be that kind of tensioner, had nightmares with this type in the past on 2 different Picasso's :( Oh well I will figure out the bolt size and invest in a nice extra long spanner :)

 

Went out t it last night and started it and annoyingly the battery light went off,, alternator must be on the way out but I might postpone it until tomorrow when it is supposed to be dry, did front brake pads on a friends car yesterday in the rain, not much fun!

 

I will take some pictures along the way and see if I can coddle together some kind of guide, if I have to take that nightmare under tray off I might as well give it an oil and filter change at the same time.

[PembsPanther]

Just went to start it this morning and battery light still off as soon as I put it under load though it came back on, 11.52 the reading this morning. For kicks, as Brian suggested I gave it a whack with a rubber mallet and it jumped back into life putting out 13.64 volts! Alternator or connector we will see when I take it apart, lol the joy! :)

[BrianH]

Sounds like the brushes in the alternator have worn out to me then - exactly what i had happen. Mine chose an ideal time to do it - I was in the middle of Belfast city at the time, with a ferry crossing before getting home to deal with it.

 

I ended up managing to find somewhere to fit a new alternator - Was the only way of sorting it at the time, as was without tools and couldn't find an alternator for it over there either to buy!

[PembsPanther]

Well it is on and working well :) Nightmare to do though, I must have totally looked at this from the wrong way surely? No access to the alternator bolts at all and removing the black fibreglass headlight housing that runs the whole width of the car was impossible, only thing I could do was smash a hole in the back of it so I could gain access to the bolts, crappy engineering! Why am I not surprised FORD!!!!

 

Just need to go and put it all back together now, the stuff I took off trying to get that housing to move :( oh well back to it!

[BrianH]

I managed to get that bit out (think it was when i was replacing the radiator though not 100% sure that was the job in question). The place i got to do the alternator I'd said take it off and leave it off (meaning put it in the car I'd put it back later on). They must have chucked it away as a few days later I realised i didn't have it!. You can take those pegs out, but your bound to lose most of them in the process anyway. If yours is a mk2 it may be different though.

Either way you've done it - I've seen/done worse - changing the starter motor on a mondeo is a complete pig as you have do do it from underneath, but its up at the top right below the manifold so access is not good.

[mikej]

Mr panther, pm me your mobile number and i'll give you a call mate, trust me i'll save you a whole load of pain lol, don't try taking it out it's not necessary.

Regards 

Mike.

[mikej]

Ok guys if you ever suffer from this issue there is a 90% chance your brushes are worn, there is no need at all to remove alternator as all can be sorted with it in situ. Simply remove regulator from alternator as this incorporates the brushes. Firstly remove black cap from alternator and you should find regulator within held in place by two bolts, remove it and replace brushes in regulator, very easy to do with a soldering iron and brushes can be had for peanuts on Ebay, reinstall regulator, refit cap and lead and job sorted. From memory all you need is a deep 7mm socket for cap and reg, possible 14mm for lead? and small 1/4" ratchet etc, soldering iron etc. Once you remove your regulator have a look at the slip ring, if one or both of the rings is NOT shiny copper then the brushes are failing to make contact due to wear. I would advise to clean up the slip ring prior to fitting new brushes,  use of some fine abrasive paper etc. Hope this helps some of you...

 

***DISCONNECT YOUR BATTERY FIRST GENTS***

Edited August 5, 2016 by mikej