I wish I could remember exactly how I did it but I'm virtually certain I left that bracket on the car when I swapped out the alternator on my 116, and I didn't bend anything.

#3 bolt threads into a welded nut on mine. If the nut on yours is spinning, you need to put an open end wrench on it. If ratchet will not fit #3 bolt head, use a box end wrench with a long pipe for leverage. Sounds like your in deep doodle. Vstech has ran into that and can give you more advice. What ever you do, do not round off #3 bolt head or nut.

yeah, it can be done, but it's a pain.
much simpler to take it all down at the same time.
the 116 has a bit more room to work in than the 123 too...

steve, the #3 bolt should be threading into a bracket... I think #2 nut is welded on most brackets, but I've run into plenty that were loose... annoying... I love my mig!

Welded nut on the bracket is what I meant. This is from memory so could be wrong.

Got it out!
 

I got the alternator removed today. It CAN be done without loosening the #3 bolt. It wasn't pretty, though. What I didn't understand was how the #1 bolt came out. With the nut off the adjuster, the alternator shoves all the way back down the track and the adjuster bolt comes free of its bracket. With the #2 bolt removed from the bottom, the alternator can slide even though #3 isn't loose. Maybe because of the #3 not being loose, I couldn't get the alternator moved in the last 1/2" of the slot, so I had to resort to bending the adjustment bracket to free the threaded adjustment rod which is attached to the #1 bolt. Then the #1 can be backed out and the alternator falls out.

I got lucky putting it back in, which in this scenario (with the mounting bracket still attached to the engine) the hard part is getting the bushing sleeve that the #1 bolt passes through to line up when re-installed. I put it on a retracting magnet and slowly pushed it in while gently manipulating the #1 bolt.

I admit that bending the mounting bracket is bad form, but it may be the only way to do it if the bracket is held immobile by a stuck #3 bolt as in my case.

Thanks to everybody for all your help!

I have had to re & re mine twice now over the years. 84 300D.
I removed the alternator with the adjusting bracket attached.
Once on the bench I remove the bracket and install it back into the car.
The alternator will go back in easier without the bracket attached.
I install the bottom bolt then swing it up under the adjusting bracket and slip the bolt in place from the front.

Here's a picture of the bits:-

http://www.peachparts.com/shopforum/...8&d=1298541006

From this thread:-

http://www.peachparts.com/shopforum/showthread.php?t=294656

Too late to help now, but I would have sprayed or tried to wick penetrant onto the FRONT of the nut/bracket for #3 near the threaded end not near the bolt head end at the REAR of the bracket. The pic shows liberal use but on the head end, not the thread end.

If that didn't work but you were able to get it out, I'd have recommended taking advantage of the exposed underside/back of the nut and tried to free it up with more penetrating oil.

see post #5. I recommended he soak the opposite end from the picture...

I soaked both sides of that bolt. Repeatedly.

I will admit now my big mistake: when I removed Bolt #1 and took out the alternator, I had my grand opportunity to have room to turn that #3 bolt and loosen it, because the #1 bolt was out of the way. But I was too excited that I got the alternator out, and forgot to do this! :rolleyes:

Hi
I have an 85 300CD and am stuck on the number 2 bolt. I have tried PB Blaster various sockets and box wrenches and it is not budging. I've rounded my nut finally. Is there a change it is a left handed bolt? I have even mounted a wrench on the nut and place a jack under the free end to force it. It goes up about 2 inches and then nothing, HELPPPPP
Thanks
Zen

Definitely not a LH bolt. Usually, if corrosion has taken over, application of heat makes the difference. Don't focus the heat in too small of an area, especially on aluminum, or you may have more serious problems.