quattro Digest, Vol 97, Issue 36

[Tom Leppke-Hennig]

> Date: Tue, 29 Nov 2011 21:11:49 -0500
> From: "Radek" <radek at istar.ca>
> To: <quattro at audifans.com>
> Subject: Dismantiling a Bosch alternator - is there a trick?
> Message-ID: <3D967AE4E3DC4A4AA06E9003D2D7ABF0 at Compaq>
> Content-Type: text/plain;	charset="iso-8859-1"
>
> This is out of my Eurovan, a 120 Amp alternator that has a bad regulator
> and worn out bearings.  I've been trying to take the two halves apart,
> removed four screws that obviously hold the halves together, removed the
> pulley, removed four screws that were hidden behind - something is still
> holding it together.  No other screws are visible.  Any tricks you know
> and I don't?
> Thanks.
>
> Radek.
>
Radek,

You are close. The aluminum halves captivate the laminations that make up
the iron core of the stator (the non rotation coils in the body of the
alternator) are pressed onto the laminations. Once you have it un-fastened
to the point you have it, tap/pry the aluminum casting off of the
laminations. Opposing prybars progressively walked around the perimeter of
the laminations works well if you have two pry tools.

With apologies to Huw, go easy on the violence. The 120A alternators have
delicate castings.

Also, when you do get it apart, bring your A-game to the task of getting
the rear bearing off. It is very close to the slip rings. They are small
and delicate compared to the older designs and won't tolerate bumping or
prying.

Good luck.

Tom LH