300tdi alternator

[Intrepid]

G'day all.
I was on my way from Wollongong to nambour with my two young kids to see the father in law who's not got long now.

Basically 30km from Cessnock the defender starts to squeal. The alternator bearings (or something) failed and alternator fan is rubbing furiously on the body of the alternator. I made it in to cessnock and managed to order a new alternator which should be here late morning. I want to know, is there any things I need to be aware of replacing the alternator? Obviously disconnect the battery first... I found the big long bolt on top and I figure there's a smaller one on the underside?

I'm hoping it will go smoothly, though doing such jobs on the side of the road ensures that it will be a bit of a chore! She's A 300tdi 110 defender. Any tips to get me motoring again appreciated.

Thanks all.
Joshua.

[TonyC]

Hi Joshua,
Just be aware there are two sizes of pulley, and correspondingly two different belt lengths.

That said when I ordered one for an (almost) side of the road replacement it didn't have a pulley, and needed a rattle gun to swap them over.

I hope it all goes well.

Tony

[Gumnut]

Hi Joshua,

Sorry to hear or your electro-mechanical and family troubles.

As stated, a new alternator may (will) not have a pulley. If not, the old one will require removal. This will undoubtedly require partial disassembly in order to hold the armature in a vice, and the use of a rattle gun.

The shaft does have a hex socket, however it is made of some sort of plasticine like substance and will not withstand the use of an Allen key and ring spanner without rounding out......

No need to ask how I know this, or at what exotic or remote location I found out. Suffice to say it was not near my tools, a vice, a rattle gun or a spare complete alternator, or anything much else for that matter.

In the last respect, you are streets ( literally!) in front, as there is a well stocked reliable supplier within walking distance of a train station at kotara if you end up in a world of grief, and decide that complete second hand, or assistance with new built up is required.

Hope it goes well,and let us know accordingly.

Cheers,

Gumnut

[Intrepid]

Thanks for that gem of info. If it has no or the wrong pulley I will take it somewhere to do the swap. That said, I think I have spares of both belt sizes?
The guy I ordered the part from asked about the pulley so I'm hopeful...
Thanks.
Joshua.

[Intrepid]

Well what a day! Got the part and started dismantling in 30kt NWLies and thought, bugger this. I took it to place where the guy in line behind me at the parts shop said he might be able to help out. he was a mechanic...

Well the owner, Carl Walters, bent over backwards to help. The part that was sent was wrong. the problem was actually a flogged out pulley and armature. Given the obstacles he repaired it instead. He remachined both parts and fit and fabricated some bushes, then sealed it all with loctite. 2.5hrs later I'm driving again.

Feeling very fortunate right now!

Until the next catastrophe, thanks.
Joshua.