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#1
10-25-2003, 05:42 PM
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Alternator is buggered
Finally got to the root of the alternator problem today. It was not straight in the mounting bracket. Why? Because the holes are elongated. Here's an overall view:
 Here's how the lower bolt should go through:  and here how it actually goes through:  Is there any hope for this thing, or must I buy another one? P.S. I struck out on alternators at the junkyard today, but bought a bunch of other stuff.
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Rick Miley 2014 Tesla Model S 2018 Tesla Model 3 2017 Nissan LEAF Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro Chain Elongation References Last edited by Rick Miley; 10-27-2003 at 01:02 PM. 
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#3
10-25-2003, 07:43 PM
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Rick
If you have an impact wrench to remove the pulley nut its easy to change the outer case if you can get a good one. I had a bad case (bad holes like yours) w/ good alt & a bad... , well you get the idea. An impect wrench is the key to that job 
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 1985 Euro 240D 5 spd 140K 1979 240D 5 spd, 40K on engine rebuild 1994 Dodge/Cummins, 5 spd, 121K 1964 Allice Chalmers D15 tractor 2014 Kubota L3800 tractor 1964 VW bug "Lifes too short to drive a boring car"
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#4
10-25-2003, 08:32 PM
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Rick I fixed mine when it did that (only the bottom bolt though)with JB weld and then redrilled it . It's been fine since.BTW that is a service item (retighten alternator mounting bolts) at every oil change.Good luck.
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Democracy dies in darkness, you have to kick at the darkness till it bleeds daylight
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#6
10-25-2003, 11:29 PM
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Same thing happened to mine on the 409d. Strange, never seen it happen on another vehicle. Someone wrote on a thread here within the past six weeks or so, that they can be drilled out and sleeved to solve the problem.
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1977 300d 70k--sold 08 1985 300TD 185k+ 1984 307d 126k--sold 8/03 1985 409d 65k--sold 06 1984 300SD 315k--daughter's car 1979 300SD 122k--sold 2/11 1999 Fuso FG Expedition Camper 1993 GMC Sierra 6.5 TD 4x4 1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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#7
10-26-2003, 12:38 AM
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I think Ricks holes are so worn that by the time you drilled it out to sleeve it there would be nothing left
 .The JB weld does last , I did it on my car 2 1/2 years ago and it's still holding. Just tape the bottom of the hole , mix some up and ladle it into the hole , tapping it to get air bubbles out , fill it to overflowing and let it set for 24 hours then drill it out with a drill press. It seems really soft but it holds up  . One package will fill both holes , good luck.
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Democracy dies in darkness, you have to kick at the darkness till it bleeds daylight
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#8
10-26-2003, 08:05 AM
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Randy, don't forget about the $35 core charge that I probably wouldn't get back once they see this one.
JBWeld it is. Thanks Kyle.
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Rick Miley 2014 Tesla Model S 2018 Tesla Model 3 2017 Nissan LEAF Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro Chain Elongation References
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#9
10-26-2003, 09:21 AM
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At our local pull and save, an alternator is only 12.99.
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1977 300d 70k--sold 08 1985 300TD 185k+ 1984 307d 126k--sold 8/03 1985 409d 65k--sold 06 1984 300SD 315k--daughter's car 1979 300SD 122k--sold 2/11 1999 Fuso FG Expedition Camper 1993 GMC Sierra 6.5 TD 4x4 1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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#10
10-26-2003, 11:06 AM
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No, Natalie. You're thinking of the new governor of Kalifornia.
Cheers, Wes
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#11
10-26-2003, 12:58 PM
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Kerry , Is that the same yard that sold someone ( you ?) a manual transmission for $67 ?
If yes, I think we should have one of the get togethers IN that yard....
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#12
10-26-2003, 01:05 PM
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Natalie, since you are a Canuck I will interpret this for you..
Prenator... the 97 lb weakling before he discovers weight training. Terminator...Film star in movies which defy physics. Anternator ... the Prenator after his muscles have turned to flab.
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#13
10-26-2003, 01:36 PM
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Yes, same yard. Last week when I was there they were having a sale on transmissions--any tranny $27.99. There was a 115 body 230 there along with the old finny I posted about.
They say that they get 300 cars per week into that yard. The cars don't stay in the yard for that long. Probably less than a month.
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1977 300d 70k--sold 08 1985 300TD 185k+ 1984 307d 126k--sold 8/03 1985 409d 65k--sold 06 1984 300SD 315k--daughter's car 1979 300SD 122k--sold 2/11 1999 Fuso FG Expedition Camper 1993 GMC Sierra 6.5 TD 4x4 1982 Bluebird Wanderlodge CAT 3208--Sold 2/13
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#14
10-26-2003, 05:44 PM
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I tried the junkyard yesterday and there was a W115 300D, a 78 240D and a 79 240D that were not there the last time. All three were missing their alternators. I'm starting to thing they pull them before even putting the cars in the yard.
I couldn't bring myself to do the JBWeld thing, and I really need the car this week, so I found an alternator at AutoZone today. Went down to buy it and whaddyaknow, those holes are sleeved.  In fact the sleeves made the alternator too thick to fit on the car, so I had to do some grinding to get the thing in there. I reused the busted adjuster/mounting bolt and just levered the thing into place. Got everything back together and she's purring like a kitten now.
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Rick Miley 2014 Tesla Model S 2018 Tesla Model 3 2017 Nissan LEAF Former MB: 99 E300, 86 190E 2.3, 87 300E, 80 240D, 82 204D Euro Chain Elongation References
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#15
10-26-2003, 05:58 PM
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I am glad you got it going...
But a combo of a sleeve and the JBWeld to hold it in place would be a perfectly legit fix... just for reference the next time....
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