Alternator removal

S

Susan Rivera

New Member
Jun 16, 2019
5
Boat Info
240 Sea Ray Sundancer 2008
Engines
454 Mercruiser w BRAVO III Drive
Hello Boaters,

I started what in thought was an easy alternator replacement on my 2008 Sea RAy Sundancer with 383 Mag stroker. All was good until I got to the bottom bolts attaching the alt to the bracket. Bolts are rusty and I cannot get them off. Please help. Any suggestions? Thank you.
 
Is it possible to remove the whole bracket from the motor?

That way you could heat the bolt with a torch once the whole assembly is off the boat and on the workbench.
 
Penetrating oil and a "little" heat from a propane torch. Work the wrenches back and forth till they come loose. Keep the heat away from hoses and wires.
 
They shouldnt be that rusty to begin with.
If it has the 2 bolts at each end, break them and replace them
 
Espos4 said:
Is it possible to remove the whole bracket from the motor?

That way you could heat the bolt with a torch once the whole assembly is off the boat and on the workbench.
Click to expand...
I dont think i can remove the bracket. I will take a look. Thanks.
 
hottoddie said:
Penetrating oil and a "little" heat from a propane torch. Work the wrenches back and forth till they come loose. Keep the heat away from hoses and wires.
Click to expand...
Can in use the heat gun inside the engine room? What about the fuel tank?
 
Susan Rivera said:
Can in use the heat gun inside the engine room? What about the fuel tank?
Click to expand...

Make sure you don't smell any fumes to start

I would set up a fan to blow any potential fumes out of the bilge.

Be cautious with what you are heating in there, want to use a tip on your heat gun to focus the heat on the desired bolt/nut....
 
Susan Rivera said:
Hello Boaters,

I started what in thought was an easy alternator replacement on my 2008 Sea RAy Sundancer with 383 Mag stroker. All was good until I got to the bottom bolts attaching the alt to the bracket. Bolts are rusty and I cannot get them off. Please help. Any suggestions? Thank you.
Click to expand...

Are you referring to the bolt that goes through the alternate into the bracket - or - the bolts that go through the bracket into the block?

I had an alternator pivot bolt lock in my bracket but I was able to remove the bracket from the block. To date the bolt is still inside the bracket - I ordered new brackets to replace.

-Kevin
 
Susan Rivera said:
I dont think i can remove the bracket. I will take a look. Thanks.
Click to expand...

I do not have diagrams handy but if was mounted like the alternator on my 8.1s the bracket was just under the heat exchanger and two larger bolts held the bracket on.

-Kevin
 
This is what my bracket looked like (this was the good one).
IMG_20200703_075318286.jpg

And this was my mess:

IMG_20200703_075204133.jpg

The head eventually snapped off, drilling out did not work and I was able to remove the rear bolts. The alternator would still swing on the bolt but the bolt was frozen in the bracket tube.

-Kevin
 
Alternator seized on jetboat once. Lots of torque on bolts finally got it out. Now I take it off every winter as I store boat outside without any heat in engine room. Starter after 2 years would not work it seized also. It also comes off in the winter rest of engine looks good every spring.
 
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