alternator removal - 986 Forum - The Community for Porsche Boxster & Cayman Owners

brp987 · 01-11-2023, 01:35 PM

I am trying to remove/replace an alternator on my 2001 986S. I have Wayne's book. He describes tapping the idler pulley to remove a bushing. I don't understand the significance of this. My new alternator has this bushing installed already. I don't see how it is possible to remove the alternator. I removed the lower mount bolt. I can't remove the upper mount bolt because it is so long that it hits the firewall. I'm trying to pry the alternator up from from where the pulley bolt rests but it doesn't budge. Getting worried...

brp987 · 01-11-2023, 02:31 PM

Update - I have the long pulley bolt removed by finagling things around. But to no avail. The alternator is pivoting from where this long bolt used to be but I still can't get the alternator to budge.

Wayne's book says it may require significant tapping with a hammer and drift on the long pulley bolt to remove the alternator bushing. Believe you me, in my current state I was more than willing to do this however the bushing did not budge.

911monty · 01-11-2023, 03:04 PM

You're going to need a bigger hammer.

See that bushing in the new alt. when you torque that bolt the bushing is drawn tight against the mounting bracket. The friction prevents the alt removal.

Put the long bolt back until snug then back out about 2 turns. Now get a 2 to 4 pound sledge hammer and a 10-12" punch DO NOT USE A CLAW OR FRAMING HAMMER as they have hard faces and can cause chips at the speed of sound. Wearing goggles Take the punch to the center of the bolt and give sharp raps until bushing releases. You do not need to remove the bushing.

brp987 · 01-11-2023, 03:16 PM

Thanks for your reply. I tried with a ~ 2lb sledge and a 12" long 1/2" ratchet extension bar. Gave it serious whacks. I'll try again...

brp987 · 01-11-2023, 03:51 PM

I could not re-install the long bolt. However, by tapping the alternator forward flange, then rocking the alternator back and forth while prying the rear flange I was able to walk the damn thing out. Miserable job.

The problem now is that it seems the rebuilt Bosch I'm trying to install has the bushing in the compressed state. The alternator will not go on. I'll have to remove it from its partially installed position and lightly file the bushing. Awful job.

Sean F · 01-12-2023, 02:31 AM

You can wind the bushing back by putting the long bolt through a couple of large sockets, to act as spacers, and then into the back of the bushing. Tighten the bolt and it will pull the bushing back.

Obviously, this can only be done with the alternator out of the car so it doesn't help with getting the old one out.

Good luck.

Starter986 · 01-12-2023, 09:57 AM

You may find that reinstalling the alternator will require some finagling.

Exercise patience. Patience. Patience. Patience.

brp987 · 01-23-2023, 11:59 AM

Well, this job has a happy ending. I took a fine file to the front mounting ear - took off maybe 0.01 to 0.02 thou, in order to get a net fit so the rblt alternator would slide into position. Put in a new battery for good measure. Dash lights all turned off, so all good - or so I thought. See new thread re: clunk in steering...

maz8062 · 08-30-2025, 08:40 PM

Quote:

Originally Posted by Starter986

You may find that reinstalling the alternator will require some finagling.

Exercise patience. Patience. Patience. Patience.

This is the part of the job that very few YT videos or comments online address. Yes, it is hard to remove but installation is anything but “reverse of removal”. Intuitive it is not.

Having owned my Boxster for 4 months and tackled several jobs, I’m convinced this car was designed explicitly to discourage home mechanics from working on them, with the techniques hidden away in dealer only manuals, PIWIS etc. The internet and kind folk had other ideas and were grateful for forums like this.