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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by stoney on Sun May 1 10:59 CST 2005
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last visit: Wed Oct 22 17:48 CST 2014

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Decided to swap the no name rebuilt alt I put in 2 years ago when my OEM died in the middle of nowhere. Bought a 740 alt (88) off ebay for $20. 80 amp unit same size as 240 alt but different part #. Same/same unit.

Well the adjuster snapped off as it was rusted to shit. No biggie - that's what the big screwdriver is for...
The pivot bolt was frozen solid. Nut cam off the back end but the head would only turn WITH the alt. OK Bolt is frozen/rusted to the alt body inside the sleeve.

When the alt is swung all the way down, clear of the adjuster, the top bolt of the mount is accessible and when you swing it all the way up you can get to the twoi bottom bolts. The finagle it out thru the hoses and shroud.
Yup- bolts frozen solid so out comes MR GRINDER with a Metabo metal carbide blade- zip zip its done and the mount bracket is free.
Lucky I had decided to swap out the bushings anyway.
Home Despot has the replacement bolt- 5/16ths x 6 in in Rhodium plate. plus 2 washers and 2 nuts ( a sapre so you dont have to go looking when you drop the only one you bought).
Install the bracket(with the ground cable) and mount the new alt and hook up wires and belts and use Mr 36 in Screwdriver to set the tightness of the adjuster.

Done - Time 1 1/2 hrs. No skinned knuckles. 1 lady helped locading 2 doors and 5 galons of paint at HD.

The 740 80 amp alt is direct swap to the 240 despite the contrary being posted here bu others. If its a B230F alt its same/same.

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by Steve on Sun May 1 13:48 CST 2005
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last visit: Fri Oct 24 07:16 CST 2014

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I hope you used antiseize on the new bolts.

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by someone claiming to be Alex Z. on Sun May 1 14:57 CST 2005 [RELATED]

Loctite on the lower alt. bolt for sure. I've had the bottom bolt fall out after the nut backs off too many times to remember on my 240s. Sometimes you just have to learn the hard way.

--
alex

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by Steve on Sun May 1 16:05 CST 2005
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last visit: Fri Oct 24 07:16 CST 2014

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Wow: never happened on any of my 740/940s. Must be a different arrangement.

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by Art Benstein on Sun May 1 16:16 CST 2005
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last visit: Fri Oct 17 20:10 CST 2014

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Vague memory from ripping that 700 alternator from the junkyard: The nut on the pivot bolt was a locknut. Makes sense for the application anyway. Now the bolt into the block on a 240... that is another story. I've read some stories here about heli-coil, and so forth.
--
Art Benstein near Baltimore

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by Art Benstein on Sun May 1 13:31 CST 2005
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last visit: Fri Oct 17 20:10 CST 2014

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Wow. Pivot bolt frozen to the alternator housing? Must be full of that white aluminum rust that forms and expands when the two metals stay wet-- all I can think of as an example at the moment are Corona wheels and steel hubs where the water collects when the hubcaps are missing.

Say, I had not heard the 740 alternators would not work in the 240. I think that was one of the first jobs I did on a Volvo, shortly after you helped me figure out my fuel pressure adapter. I thought a 700 alternator was ideal because in the junkyard, they were high and dry. Not much back bending to remove. I think I had to swap pulleys if I recall. But it went on a B23 in the 240.
--
Art Benstein near Baltimore

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by stoney on Sun May 1 15:09 CST 2005
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last visit: Wed Oct 22 17:48 CST 2014

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Just got back from a night run to check the alt with full load (Headlights, wipers, blower, A/C) and it seems to be fine. No dimming and the dreadful idle flicker is history.

The rebuilt unit was also a Bosch but had a definate problem with the guts. New brushes and a new diode didn;t help at all. VR is Ok so it may have been a bad armature winding job (had a Crown tag on the outside but a chinese inspection tag inside when I did sone surgery this afternoon).

The pivot bolt was frozen solid. It took a hell of a lot of PB and a BFH to free it and the bore was all pitted and chewed up looking. Bolt was not a plated one.

The replacement is rhodium plated and now coated with so much anti sieze my fingers still look like I am a secret admirer of the Silver Surfer.

I figure I'd drop it off at a rebuild shop I know in Mt. Vernon NY and see what a job they do on it. They do all the steel shot blasting on my firms Concrete Air Meters and having hung around their shop they do a damn good jopb for $60.

As for the reman alt that was in place...It was sourced from AutoZone and I'm not into taking another "Shanghai Surprise" as an example of their lifetime warranty.(Its a matter of $$ spent on mfg. I know that rebuild firms cut corners to save sheckels but I'm tired of bad work and mismatched brake caliper halves and the like!).

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by Art Benstein on Sun May 1 15:47 CST 2005
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last visit: Fri Oct 17 20:10 CST 2014

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Had to look up Silver Surfer but the image was even funnier without the drawing.

Like you, I've tired of giving the hairy eyeball to those "lifetime" reman parts set on the counter. You are supposed to take them out of the box to see if it matches your part, but instead you need to inspect it for being properly and completely assembled. This always leads to my rant on the economics of the reman industry, but that hasn't changed in the 35 years I've been buying auto parts. I remember being so disgusted with a starter, I brought tools with me to check out the next one, in hopes of saving me a third trip.

That 740 alternator I mentioned snagging so easily at the junkyard, was mainly for the housing, which had egged out around the pivot bolt, which itself was only a skinny replica of its original self -- almost the opposite of the trouble you had. Rusty at RPR sent me a new pivot bolt on that one.
--
Art Benstein near Baltimore

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Alt replacement-it ain't as easy as you think when the bolyts are rusted solid. 200

posted by stoney on Mon May 2 16:17 CST 2005
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last visit: Wed Oct 22 17:48 CST 2014

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Well if Stainless was really STAINLESS I'd of shagged down to Goldberg's and got it in 5/16"x6" SS...

But outside of Honest to Adolph HILTI Stuff I an;t seen REAL Stainless in at least 10 years.

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