jeepdreamer

I was trying to pull the big wire off the alt on my 91 and the stud snapped off. Its the bigger wire that has the plastic shroud around it. Is this stud replaceable? If I just DXed my alt I'm kinda screwed.... If it can't be fixed can you point me at a relevant thread for finding an alt from a different vehicle that will work. Limited junkyards here in Germany and a lot of the threads I've found in the "search" mode were about the renix motor or grinding some big case version... I could use some advice guys... Thanks!

tgordon

Not replacable by the average DIY.
My best recommedation is to get a remanufactured one.
And see if yours will be accepted for the core exchange/charge.

jeepdreamer

Nuts... I was afraid someone was gonna say that. Don't suppose I could just solder a connector on whats left sticking out and make a disconnect a little ways up instead? What does the plastic thingy do and is it really needed? Hate to sound hack but it would be a while even if I ordered one tonight before it got here to Germany.

tgordon

If the plastic thingy you mean is what I think you mean. Yes, its very important. It is an insulator for the positive side of the alternator output. PM me your email addy and I will send you a file that is an exploded view of the alternator. Then we can be certain we are both talking about the same thing.

Turbo X_J

Google "positive alternator terminal" & find someplace that will ship to Deutschland.

Marcucco

You can hack it, but the chances of you doing a functional repair in-place and right-now are REAL slim.
You're talking about some serious power here, big crisis if you mess up, (even a little).

The individual replacement parts are available, but if you want to try and buy one of these and one of those you're gonna pay for the privilege.
You'll get off cheaper buying a complete rebuilt unit, honest.

Radi

I looked up the Bosch replacement. It fits the following vehicles:
(verify the used unit matches your current one before you buy though)

Buyer's Guide: BOSCH AL6509N Alternator / Generator
CHRYSLER DAYTONA (1988 - 1993)
CHRYSLER DYNASTY (1988 - 1993)
CHRYSLER FIFTH AVENUE 1989
CHRYSLER IMPERIAL (1990 - 1993)
CHRYSLER LEBARON (1988 - 1995)
CHRYSLER NEW YORKER (1988 - 1993)
CHRYSLER TC MASERATI (1990 - 1991)
CHRYSLER TOWN & COUNTRY (1988 - 1995)
DODGE 600 1988
DODGE ARIES (1988 - 1989)
DODGE B150 (1990 - 1994)
DODGE B1500 (1995 - 1998)
DODGE B250 (1990 - 1994)
DODGE B2500 (1995 - 1998)
DODGE B350 (1990 - 1994)
DODGE B3500 (1995 - 1998)
DODGE CARAVAN (1988 - 1995)
DODGE D150 PICKUP (1990 - 1993)
DODGE D250 PICKUP (1990 - 1993)
DODGE D350 PICKUP (1990 - 1993)
DODGE DAKOTA (1988 - 1998)
DODGE DAYTONA (1988 - 1993)
DODGE DIPLOMAT 1989
DODGE DURANGO 1998
DODGE DYNASTY (1988 - 1993)
DODGE GRAND CARAVAN (1988 - 1995)
DODGE LANCER (1988 - 1989)
DODGE MINI RAM 1988
DODGE OMNI (1988 - 1990)
DODGE RAM 1500 PICKUP (1994 - 1998)
DODGE RAM 2500 PICKUP (1994 - 1998)
DODGE RAM 3500 PICKUP (1994 - 1998)
DODGE RAMCHARGER (1990 - 1993)
DODGE SHADOW (1988 - 1994)
DODGE SPIRIT (1989 - 1995)
DODGE W150 PICKUP (1990 - 1993)
DODGE W250 PICKUP (1990 - 1993)
DODGE W350 PICKUP (1990 - 1993)
JEEP CHEROKEE (1991 - 1999)
JEEP COMANCHE (1991 - 1992)
JEEP GRAND CHEROKEE (1993 - 1998)
JEEP GRAND WAGONEER 1993
JEEP WRANGLER (1991 - 1998)
PLYMOUTH ACCLAIM (1989 - 1995)
PLYMOUTH CARAVELLE (1988 - 1989)
PLYMOUTH EXPO (1988 - 1989)
PLYMOUTH GRAN FURY 1989
PLYMOUTH GRAND VOYAGER (1988 - 1995)
PLYMOUTH HORIZON (1988 - 1990)
PLYMOUTH RELIANT (1988 - 1989)
PLYMOUTH SUNDANCE (1988 - 1994)
PLYMOUTH VOYAGER (1988 - 1995)

jeepdreamer

Holy smokes... I went to sleep a few hours and look at all the posts! Thanks guys for the help and information! Gotta love this site.
The replacement stud shown by Turbo XJ is what broke. The plastic shroud is what goes around it. Its black, kinda more rectangular in shape, and has a small locating nub/pin/dowel thing to keep it oriented in place. Is it an isolator as tgordan suggests...I'm not sure? I am pretty sure its there for a reason but my first thought was it was just a shroud to surround the bigger wires terminal. I'm heading down to work on the jeep mow so I'll look more at it in a minute. I'll be back later and will try and post pics.
I was hoping to be able to just fix it so I can make this thing run and decide if the rest of the jeep is worth saving. Lots of rust and other needs but if it runs like crap then I'd prob. just part it out... I'll head over Sunday to the junkyard on Grafenwohr and see if there is another alternator there somewhere I can use. If not, and if I think I can save the Jeep... I'll likely just order a replacement. I hate that I broke it like this but honestly the current alt is pretty grungy looking and may have been due for one anyway.
Thanks again everyone... I'll be back.

Radi

The important function is to isolate the Alternator output stud from the grounded metal alternator case. If they touch you'll have a short with very high current.
The outer shroud that covers the attaching nut isn't too important, just the part that isolates the stud from the alternator case.