Ok, so I have determined that I need to replace the alternator. Today had some time off finally and got to removing it. Top mounting bolt comes out fine, but when I put it back in, and try to remove the bottom one, it required so much torque that the head is now rounded, using a close-ended wrench or socket. So... now I remove the top bolt to see if I could get on the bottom one at a different angle and the alternator will pivot on the bottom bolt. Is this a situation that an 'easy-out' will solve or do I have bigger problems?

 

its a steel inside aluminum deal. the bolt is seized inside. if you get it out then there shouldnt be an issue as long as the threads stay in the hole. but since the head is rounded off and its that tight, it may be hard to get out. use a set of torches to heat up the hole with the threads and then use vise grips and try to use a pipe or pry bar to break it loose if necessary.

 

from your response I assume that the bolt is only threaded into the rear hole of the bracket? and just sits in the bushing at the front of the bracket?

 

correct

 

http://www.sears.com/shc/s/p_10153_12605_00952060000P

I've used these on rounded t-case and bellhousing bolts and they always came out.

 

these would work but as tight as the bolt is he would still need to heat up the hole.

 

ended up using a hacksaw blade and cutting through some of the alternator case and cut the bolt at both ends
that bolt is good and welded into the alt case
thanks for the replies