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Old 11-11-2010, 10:03 AM   #1
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Default Replacing alternator

I'm going to attempt installing a new alternator on my 96 sport. Are there any tips, tricks or things I need to be aware of or just roll up my sleeves and get the job done? Advice? Thanks
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Old 11-11-2010, 10:06 AM   #2
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nope just do it. Having a buddy to help re-tension the belt is good too.
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Old 11-11-2010, 03:08 PM   #3
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Thanks for the tip. Any special tools required other than the usual stuff like ratchet, sockets, wrenches, & pry bar?
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Old 11-11-2010, 03:10 PM   #4
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nope no beers till after its done makes things go alot faster also
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Old 11-11-2010, 04:13 PM   #5
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Disconnect battery.
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Old 11-12-2010, 08:18 PM   #6
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I just replaced mine on 11/09. Disconnect the battery. Plan on replacing the belt. I tried using my old one and it squealed like hell. Use a good Gates belt. I wish Jeep had mounted this higher up rather than down so low almost at the undercarriage!
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Old 11-12-2010, 09:29 PM   #7
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20-30 min, i can take out and replace the Alt in my 87 XJ
1/2in, 13mm, 15mm (i think, for Alt bolts), 6" extension, ratchet, Shiner Bock.

*Remove battery tiedown, and battery.
*Remove Airbox. (sip beer)
*Loosen a few bolts on the power steering box.
*Loosen the tension bolt on the side of the above box, its the 13mm. (sip beer)
*belt comes loose.
*Remove two bolts holding on Alternator (they also ground it).
*Replace Alt, do opposite install (sip beer)

replace beer. beat chest. stare at completed work. sip beer.
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Old 11-17-2010, 08:42 AM   #8
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Ok, as usual, my small project has turned into a lengthy one. I finally got started on my alternator this morning before I went to work. Disconnected battery. Removed all wires from alt. Had to pull the electric fan in order to get to bolt that locks the idler pulley in place loose. Loosed the idler pulley by backing other bolt out. Not sure why I will need a buddy to help tighten the belt? Looks to me like I just need to turn long bolt until desired tension and lock in place with bolt that goes through the pulley itself. That "shouldn't" be a problem. Next I removed the two bolts that hold the alt. This is where I got stuck just in time to leave for work. Luckily I have the luxury of a company vehicle. How the heck do you get that thing out of there??? I removed the metal bracket in front of the alt. thinking I could get it down and out the front but still hitting the mech fan. Do I need to remove the aluminum bracket behind the alt that bolts to the engine block or would it be easier to pull the battery and battery tray and take it out the top? I know I can get it out, i'm just looking for the fastest method. Any suggestions before I try again this evening? Sounds like my 96 is a little different than an 87.
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Old 11-17-2010, 05:08 PM   #9
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Anybody?
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Old 11-17-2010, 06:33 PM   #10
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I think its easiest/ fastest to come out the top. Remove the battery/batt box and it comes right out. Nice and easy.
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Old 11-17-2010, 11:12 PM   #11
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yeah, for my 1987 XJ
1. i remove battery cables, remove battery tie down, battery, battery box.
2. remove the air box top/bottom,unhook the vac lines to the airbox
3. then i losen two bolts on the back of my power steering box, and remove the top front bolt. then with an extended socket, i loosen the bolt that is facing the driver side panel, directly underneath the power steering cap (down below it). These are all 13mm bolts.
4. then i keep loosening that bolt until i can remove the belt
5. then i use a 1/2in on the first bolt of the alternator, the lower one, then a 15mm on the one that is longer, the upper one.
6. the alternator fairly easily wiggles out from underneath.

I only take out the battery and box because i can get to the upper alt bolt (15mm) easier.

so the power steering pulley is the belt tensioner for mine. quite simple and a 20minute job.

i have pics, but i guess your setup might be different. I just know after a short bit of research and self teaching, the alt is a quick and easy replacement for 87's...
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Old 11-17-2010, 11:53 PM   #12
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Replaced my alternator 2 weeks ago... Its as easy as ABC...
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Old 11-18-2010, 06:22 AM   #13
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Why mess with the idler pulley? Pull the air intake box, loosen the mount bolts for the PS pump, loosen the lock nut that holds the adjuster bolt in place and back off the adjuster bolt. When loose, the PS pump will move and you can remove the serpentine belt or just pull the belt off the PS pump and you can pull the alternator.

Correct me if I am missing something but thsi should be it.
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Old 11-18-2010, 09:57 AM   #14
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Yeah, like I said and he said, the PS pump should contain the bolt to loosen the tension and it can take a lot of unscrewing before you have the slack..just be patient.

Click the image to open in full size.
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Old 11-18-2010, 10:12 AM   #15
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96 4.0s should have the simpler 2 bolt tensioner setup, shouldn't they?
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