I had my alternator start to fail while on a long drive yesterday. (The voltage while the van was running was slowing dropping, but went back to 12V once the van was shut off)

I’m in the process of installing the new one, but can’t get the thing to slide into place! Removing the original alternator required a decent amount of force from a crow bar, but now I’m having trouble replicating that force in the opposite direction. The problem seems to come from these two small metal spacers that fit into the bolt holes on the engine’s accessory mounting bracket. The spacers leave no spare room for the alternator to slide back into place. I’ve tried banging it back into place with a hammer and block of wood, and it started sliding into place, but I just can’t get it all the way in because I’m hitting it at bad angle because of the lack of room under the hood.



Any suggestions?

 

Hit the spacers with some penetrating oil, wait for awhile then use a puller to back them out a bit. The alternator should be able to be put into place then. You will have to be careful as those brackets are aluminum alloy but the spacers are steel.

 

Awesome, thanks so much for the suggestion.

I managed to get the alternator back in by using some 2x4 as a spacer against the top of the engine compartment and prying it back in carefully with a crowbar.

 

As Henry mentioned, you need to push out the spring pins prior to installation
I used a C-clamp and a large socket. When you tighten up the bolts, it will squeeze them back into place.
Taking off the dog house an help with making the connections at the back.

 

Yep, C clamp to push the bushings out from the inside of the bracket.

 

Get drunk and cuss at it.

 

I put a socket on the outside and run a bolt Through it with a nut on the inside and tighten the nut it will push the spacer and give you more space.