Step by step DIY Alternator Replacement

Had to change the alternator on my 2006 Double Cab 4.0 this afternoon so I decided to take some pictures along the way:​

Tools Needed: ​

WRENCHES​

· 10mm ratcheting preferred​

· 14mm ratcheting preferred​

​

RATCHETS​

· 3/8" DRIVE​

· 1/2" DRIVE

· 1/2' BREAKER BAR​

​

-EXTENSIONS-​

· 3/8 DRIVE 3 INCH LONG​

· 1/2" DRIVE 3 INCH LONG​

SOCKETS​

3/8" Drive - 10mm deep / 12mm deep​

1/2” DRIVE - 14MM shallow​

This is what you will be left with when you are done with the job



Step 1
you will remove the 10mm nut attached to battey hold down

Step 2​

Remove the hold down - Remove the positive & negative battery cable & remove the battery


Alternator can be see


The plug in the rear can simply be unplugged and put to the side

Unplugged


Next step would be working the plastic cover off of the 10mm nut attached to the battery cable stud. It take a little finesse to work the plastic cover off by hand

Now you can get the ratcheting 10mm wrench onto the 10mm battery cable nut






Here the cable is off






There are two small 10mm nuts that hold a bracket onto the side of the alternator. I used a ratcheting wrench to access both bolts.


front 10mm bolt

rear 10mm bolt

bracket moved out of the way



now you can remove the alternator belt
the tensioner has a 14mm head on it. It can be reached with the 1/2" breaker bar, 3" extension & shallow 14mm socket
(here you can also see the 12mm deep for the top alternator bolt)




better look at where the tensioner is for the belt


Push the bar towards the passenger side of the truck to remove tension
take the belt off the alternator pulley and set is aside

now you can move onto the top alternator bolt, 12mm



here can see the 14mm socket sitting on the lower alternator bolt.





Remove the 14mm bolt



after those bolts are removed, the alternator is ready to come out


It's take a bit of maneuvering the alternator to get it up and out of the engine bay.
This is what you are left with.



Installation is reverse of removal. Check the idler pulleys and tensioner while you are there.
New alternator installed

I put some dielectric grease in the plug before installing it back into the alternator.​

 

Just something I put together for those who many have trouble figuring these things out for the first time.

 

SAVED\

 

SAVED

 

WILL be finished tomorrow

 

nice

 

well done sir. Done might one to many times.

 

thank you sir. figured I'd add to the DIY writeups

 

Thanks for the write up bud!

 

Very good! Thank you.

 

Excellent write up with very clear pictures and detailed instructions.

Many thanks.

 

Welcome

 

Finally found one! Great write up, will hopefully be doing mine this evening now that I know how

 

Thanks for the pics and writeup. Looking to upgrade my alternator with a remanufactured 200 amp output from these guys:
http://stores.ebay.com/BNR-PARTS-ALTERNATORS-AND-STARTERS?_dmd=1&_nkw=tacoma
$195 and includes free shipping, and no core required (OEM can be my backup). $215 for 250 amp model, but then I'd have to upgrade my solenoid relay for my 2nd battery isolator. 200 amps is enough for me.

 

A quick google pulled this up, careful with those 'good deals'. My alternator was over 500 at 250 amps. Sometimes a deal is too good to be true. The top five postings off google are all warnings. DCPower is no joke.

https://www.youtube.com/watch?v=fioclq18Mng

 

Great write up, I suggest purchasing a pressure washer

 

Sticky!!!

 

Seen that. That's about the only negative entry on youtube I saw, assuming that is even a BNR alternator. Someone posted in the comments they get most of their parts from BNR and have not had problems. Their eBay rating is pretty good. Plus, I understand BNR is the parts supplier for a TW vendor. I do intend to shop there but I will have a local electric shop bench test the alt before putting it in my truck. Actually planning on getting one of their alts first for my daughter's Corolla

 

https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-8#q=bnr alternators

Yeah, could be just a fluke as well. Ya never do know.


Sheesh, I just keep finding stuff like this. This guys lasted less than three weeks.
http://www.s2ki.com/s2000/topic/1029680-high-output-alternator/

 

Sub'd!