Matt H

Can anyone tell me if this is the original underdash for a 521?

Yeah I just took it for a few laps around the block and the smoke / water went away which is a relief. Will check the coolant levels in the morning. Maybe the alternator is ok - i'm just paranoid about any small noise now haha I guess thats job done - well until something else inevitably breaks. Thanks both for your help 🫡

Hey @datzenmike I've just fired it up and burped the radiator etc. I feel like the alternator its a little louder than before (Maybe like a bit of a whirring noise) but i'm getting a steady 14.47 off the battery. Alternator noise https://i.imgur.com/QoCsARn.mp4 Is it normal for me to be getting some white smoke and water coming out of the exhaust? It hasn't been fired up for a few weeks but i'm noticing the smoke and water is pretty consistent. Please see below video Smoke / Water from exhaust https://i.imgur.com/vYlKslV.mp4

Hey @ggzilla / @datzenmike There was no keyway in this alternator. Just a circular dimple with nothing to grip onto. I ended up just hitting it with the impact wrench as I felt like I was going to do more damage than good trying to get it into a vice. Its ridiculous how tight a fit this alternator is. You have to be a contortionist to get the belt back on and fit your hands in their to tighten up the bolts let alone trying get any tools down there. I did however manage to dip my head in a full pan of coolant and engine oil like some sort of ratsun baptism which was nice. Needless to say its now reassembled. Decided to change the lower rad hose for good measure. Are you supposed torque the bolts that connect the alternator to the frame or can you just do it by feel? Its not the most accessible with a torque wrench.

Am I missing something here? The shaft and pulley spin independently so even I'm able to grip the pulley its still going to turn when I try and torque it? https://i.imgur.com/bZFeYMW.mp4

Hey @datzenmike yeah its the original pulley. I managed to pry it off and now have it on the new alternator. I read I need to torque it to around 70 lbs? How do I torque it if its moving? Do you just used the impact driver or do I need to clamp it in a vice or something?

Hey @datzenmike So I ran out and picked up a cheap impact wrench which did the job immediately. (Amazing how easy it was with the right tools) Now however the actually pulley on the old alternator seems to be stuck in place. Is there a trick to get these off or do I need another tool? I've given it a few knocks with a rubber mallet and tried some dw40 but its not wanting to come loose.

Hey @datzenmike So it looks like I need to switch over the alternator pulley. Is there a special trick to do this or do I need like an impact wrench?

OK cool thanks @datzenmike. Glad it wasn't just me as I tried every possible way to maneuver it out. Yeah the previous owner installed a bluetooth pre amp in the cab so I think it needs a stronger alternator.

Hey guys, I'm in the process of switching out the alternator. I'm using a Bosch Remanufactured Alternator AL338X which is what the shop switched it out to a couple of years back. I have bolts all loosened but have little to no space to remove it. Do I need to pull the radiator out in order to get the alternator out?

Hey @banzai510(hainz) / @datzenmike It's a newer modern alternator with an internal regulator. The external regular on my truck has been bypassed. I'll check the plug into the alternator in the morning but from what you're saying it either a loose connection into the alternator or a faulty internal regulator. Maybe thats the noise I can hear and its on its way out

Thanks @banzai510(hainz) You just reminded me I had a multimeter in the tool box. I just checked the reading and i'm getting 12.73 with the car off and but its fluctuating around 14.7 and 15.07 with the car running. Is that normal? Its also making a weird noise again Here is the reader with the car running https://i.imgur.com/WngAJVP.mp4 This is the sound its making https://i.imgur.com/bCuJ4rn.mp4 I don't know if this is related but i've just done a load of sanding in the garage if that makes a difference as everything is caped in saw dust!

I finally got around to getting the radiator fixed. I forgot to take pictures before I put it back in - but I found a guy who was able to remove the paint, locate the leak, re solder / reinforce with tin plating and repaint all for 200 bucks which I thought was a pretty fair price. It looks way better and finally stopped leaking... The truck hasn't been run for a couple of months. I've recently hooked up a trickle charger to keep the battery in good shape but noticed when I started the truck up the alternator was making a slight whirring noise. I'm curious if this sounds like its on its way out or not? I only had it replace a couple of years ago. I also noticed the running lights are twinkling ever so slightly (Hard to capture on camera). The noise speeds up when I put the headlights on etc. Car idling: https://i.imgur.com/3P4R8wA.mp4 Car idling with full beams on: https://i.imgur.com/cshY66g.mp4 Running lights: https://i.imgur.com/HeP3xbI.mp4