DIY Alternator replace
Posted: Mon Nov 10, 2014 7:16 pm
So after 200,000 miles my rear bearing in the alternator went out.
I thought it was the belt tensioner but after replacing it my clack, clack, clack noise did not go away. Closer inspenction I determined the alternator pulley
wobling. It was time to tackle this job as I can only imagine how much it would cost be to have it done.
I figured the alternator would have to be removed from the botom of the truck (I later found out the SM wants you to do so from above by removing the shroud)
1. disconnecy the battery.
2. remove upper engine cover.
3. Unplug MAF connector and remove breahter hose
4. lossen clamp to throtle body and clamp closest to air filter cover, then remove all that out of the way.
5. Untension the belt tensioner (a floor jack handle helps tremendously with and a 1/4 in. rachet) remove serpentine belt.
6. loosen upper alternator bolt (this one will be tight, 48 foot pounds) there's little room here.
7. now get under the truck and with a long flat scewdriver carefully unwiggle the body harness from the two spots mounted to the altrnator.
8. grab the regulator plug (3 wires) and carefully squeze the tab and pull it out. Unplug the oil preasure switch
9. lift up the the plastic boot covering the B+ terminal and turn it sideways carefully so you dont break it.
10. loosen the 12mm battery terminal (very little room to work here) an angled closed end wrench helped tremendously)
11. remove small plastic triangled shapped shroud mounted to the right side of the chassis.
12. get back up and completely remove the upper bolt you loosened.
13 back under the truck ,remove the lower alternator mounting bolt (very little room to work here) an angled closed end wrench helped tremendously).
14. wiggle the alternator to dismount it from the bracket. once out try and turn it around so the pulley is facing down and towards you (this worked for me
and I played around for the best poosible angle to eventually get it out; even though the stupid power steering line gets in the way, so be patiente.
15. Alternator is out . repair or replace as needed. Assembly is the reversal.
Tip: When installing back the alternator do so with the pulley facing you and play around, you'll get it in.
The hardest part for me was alingning the uper bracket hole to get the bolt thru ...took me around 15-minutes.
Hope this helps any one who wants to tackle the alternator in the Path and save hundreds!

I thought it was the belt tensioner but after replacing it my clack, clack, clack noise did not go away. Closer inspenction I determined the alternator pulley
wobling. It was time to tackle this job as I can only imagine how much it would cost be to have it done.
I figured the alternator would have to be removed from the botom of the truck (I later found out the SM wants you to do so from above by removing the shroud)
1. disconnecy the battery.
2. remove upper engine cover.
3. Unplug MAF connector and remove breahter hose
4. lossen clamp to throtle body and clamp closest to air filter cover, then remove all that out of the way.
5. Untension the belt tensioner (a floor jack handle helps tremendously with and a 1/4 in. rachet) remove serpentine belt.
6. loosen upper alternator bolt (this one will be tight, 48 foot pounds) there's little room here.
7. now get under the truck and with a long flat scewdriver carefully unwiggle the body harness from the two spots mounted to the altrnator.
8. grab the regulator plug (3 wires) and carefully squeze the tab and pull it out. Unplug the oil preasure switch
9. lift up the the plastic boot covering the B+ terminal and turn it sideways carefully so you dont break it.
10. loosen the 12mm battery terminal (very little room to work here) an angled closed end wrench helped tremendously)
11. remove small plastic triangled shapped shroud mounted to the right side of the chassis.
12. get back up and completely remove the upper bolt you loosened.
13 back under the truck ,remove the lower alternator mounting bolt (very little room to work here) an angled closed end wrench helped tremendously).
14. wiggle the alternator to dismount it from the bracket. once out try and turn it around so the pulley is facing down and towards you (this worked for me
and I played around for the best poosible angle to eventually get it out; even though the stupid power steering line gets in the way, so be patiente.
15. Alternator is out . repair or replace as needed. Assembly is the reversal.
Tip: When installing back the alternator do so with the pulley facing you and play around, you'll get it in.
The hardest part for me was alingning the uper bracket hole to get the bolt thru ...took me around 15-minutes.
Hope this helps any one who wants to tackle the alternator in the Path and save hundreds!

