Alternator bracket failure

[RicksCarrera]

Hello all

Had a surprise the other day when some smoke entered the cabin. I pulled over stoped and looked in the engine. The alternator bracket had failed causing the alt. to shift and in turn causing the destruction of the serpentine belt and oil fill tube. The smoke was caused from the shaffing rubber, no engine problem. Had the car towed home.

I have removed the alternator and the two associated tensioners exposing the failed bracket.

I will change out the bracket and the oil fill tubeI have included a pic and I hope it will attach. I'll send it now and see if the pic goes with the post, then add some further comments.

Just one Q. for now, What would be the best way to clean the fan blades and winding of the alternator?

1999 996 cab

Cheers Rick

[RicksCarrera]

Hi

Any advice on attaching a pic. Maybe the file size on the last attachment was to big with 7Meg. Thx

Rick

[Loren]

Have a look at the "How to..." here.

As a Contributing Member you are allowed up to 1MB per post. However most images are fine for viewing at 250K or less.

If you need an online image resizer try the one here.

[RicksCarrera]

Thank you Loren

I resized and attached the pic of the shifted alternator after the bracket has failed. I am quite surprised that this bracket should fail although I can see the stress it suffers. It looks worse than it is. I have removed the alternator and tensioners to expose the failed bracket. That was a pleasure and only took about 15-or 20 mins. I will need to replace the bracket, oil fill tube, and serpentine belt, put it all back together change the oil and filter and she will be as good as new. I have the manual and I enjoy working on the car.

Any recomendations on how to clean the windings and fan blades of the alternator, or is it best to leave as is. Would prefer to look at shiney copper.

I'll post as I go in case anybody has to do this.

Rick

[RicksCarrera]

I wonder if someone will know off the top of their head the purpose BEHIND this alternator bracket. After a cursory look in the manual, I can't find it yet. I suspect an oil breather? But could be part of cooling system?

Here is a pic with the alternator removed and a clear view of the failed bracket.

Cheers

[Loren]

Rick,

Are you sure the drive belt/pulley didn't cause the damage?

There are a couple of TSBs for drive belt problems:

10/99 1379 Damaged Drive Belt (dated 1-20-2000)

9/02 1379 Torn Drive Belt (dated 2-14-2003)

[RicksCarrera]

Yes I am sure Loren

A careful look at the bracket reveals the cast aluminium left eye has failed and torn away.

I am still wondering and will find out tomorrow when I order parts, what function is occurring behind this bracket. There is a hose on the right side of the bracket. I'm not sure if it is an oil breather or possibly for cooling fluid.

Cheers Rick

[RicksCarrera]

Hi all

I was reminded that I should finish this thread when I saw someone else post with what may be a similar problem.

The bracket that failed is part of the engine casing through which the cooling fluid moves.

I ordered my parts through Sunset (Jeff) and I cannot say enough good things about their service (and prices). I ordered the bracket and gasket (<$30) oil fill tube, Serp. belt, o ring for the vacum line and other miscellaneous.

I installed new oil fill tube. I cleaned and buffed the Alternator and reinstalled with new alt bracket. Reinstalled associated cooling hoses and vacum hose. Reinstalled new Serpentine belt. Changed the oil and filter, and following another thread here fully flushed the cooling system with distilled water(probably overkill) and replaced with 3 gallons of Dex cool.

I must say that I enjoy working on this car and that it all went together just as good as new.

Merry Christmas

Rick

[viper501]

Very interesting. Similar failure on my car, altough not quite as dramatic. How many miles have you got on your car? Had you had any work done prior to this failure?

[RicksCarrera]

Mine has about 60k and had no issues. Love that car.

[viper501]

In the spirit of finishing threads off, I thought I'd finalize my saga, at least for now.

Got the car back. $467 and change split fairly evenly between parts and labor. Sucks because I could have easily performed the labor had I noticed this at home. Good thing is that it seems to be running fine and the new belt looks much healthier than the one that came out of the car.

[Aussie996]

As noted in one of the posts the bracket was welded together, can you please let me know  what grade filler metal was used to complete the weld.