Old Dec 7, 2011 | 09:52 PM
  #1 (permalink)  
MMZ_TimeLord's Avatar
MMZ_TimeLord
Senior Member
Joined: Jun 2006
Posts: 1,945
Likes: 23
From: San Mateo, CA, USA, Earth, Sol, Milkyway
Post How to replace the Generator/Alternator (SRT6)

Okay, so today I had to replace the factory Generator/Alternator as it had failed.

This "How-to" contains specifics for the SRT6 setup. Tensioner release for the base and limited models are a bit different. Please refer to the serpentine belt replacement thread for more information for these models.

1. Disconnect the Battery Ground and remove the engine cover (if you have one in place).

2. Remove the passenger side (left side when facing the engine from the front) air box or CAI.

3. Remove the two clips and disconnect the radiator fan assembly. Remove the assembly.

4. Use a 15mm socket and breaker bar or LONG torque wrench to relieve the tension on the serpentine belt. If the 15mm nut breaks loose, then torque it back down and try again. Slow pressure will not break the nut loose as easily as a quick motion.



5. Once the belt is disengaged from the Generator/Alternator, you can tuck it up in the super charger idler pulley area to keep it out of the way without having to completely uninstall it.

6. Using a T50 driver on a socket wrench, loosen and remove the upper Generator/Alternator mounting bolt.

TIP: Take note of the factory paint swatches on the bolt heads if present. These make re-torquing the bolts easier later on, just match the marks up as the bolts get tight.



7. Using an 11mm socket (12 point) on a socket wrench, loosen and remove the lower Generator/Alternator mounting bolt.





8. Now you will find out if your Generator/Alternator is 'stuck'. If it can not be moved easily, take a small block of wood and a ball peen hammer. Place the wood against the upper mount and strike the wood a few times. Now take a socket that will fit over the sleeve of the lower mount and strike the socket a few times. This should shift the sleeves so you can wiggle and remove the Generator/Alternator from it's mounts.

9. Puzzle time! Turn the Generator/Alternator after it is shifted away from it's mounts until the rear is facing upward. Use a 13mm socket with a long extension (or two) on a socket wrench. Loosen and remove the nut holding the primary battery cable to the unit.



10. Squeeze the clip on the connector on the back of the Generator/Alternator to release it and wiggle it out. (You may have to use a pair of channel locks to get enough pressure on the clip. Be careful you do not break it.)

11. Puzzle time, again! You will need to turn and move and turn and move the Generator/Alternator until it comes past it's mount points towards the front of the vehicle. You will probably need to shift some of the hoses aside as well to get it to come free.

12. Success! The old Generator/Alternator is removed! Now simply reverse these steps to re-install the unit.
 
Attached Images
File Type: jpg
DSCN2545.JPG (364.2 KB, 1639 views)
File Type: jpg
DSCN2546a.jpg (623.8 KB, 1444 views)
File Type: jpg
DSCN2547a.jpg (565.7 KB, 1432 views)
File Type: jpg
DSCN2550a.jpg (788.7 KB, 1427 views)
File Type: jpg
DSCN2551a.jpg (573.2 KB, 1488 views)
Reply