Morning all,
The alternator created a week of epic proportions (slight exaggeration - but it felt like it at the time).
Hindsight says; "if your alternator has seized and stopped your engine, take it off and get a replacement".
However, I'm from 'fixing' stock, and throwing things away causes us pain.
After replacing the bearings on both ends, and repairing and screwing down the thin plate that sits on the front of the fan, the alternator was refitted.
The bearings came from BRT Bearings in Great Yarmouth: 6203 Ball Bearing, and BCH06604 Needle Roller Bearing.
Having put on a new auxiliary belt, given the engine a good service (oil change, new filters, hoses, and replaced rubber mounts under the air filter) away we went - all smiles and grazed knuckles.
Five miles down the road; nasty noises. Popped the bonnet at my girlfriend's house, and saw a lot of swarf around the nut that holds the fan and pulley onto the end of alternator shaft. Obviously it wasn't on tight?
The next morning (I needed servicing too) we return to Dad's workshop, off comes the alternator, washer goes in behind the nut, and the combined strength of two large men tightens the nut.
Back to the girlfriend's again, the same noise begins at about the same distance. Steam pouring from my ears, I call the old man and we arrange a 'meeting' for the next morning.
However, the next morning, I manage to travel 200 yards before I realise that the power steering has gone. Up comes the bonnet, and yes, the fan and pulley are now very loose, the plate on the front of the fan has come completely away - distorted, and cut clean through the brand new auxiliary belt.
Out comes the mobile, and Dad and I discuss a plan of action. As I'm sure you've all noticed, the winds have been blowing gales for a week or more, and in mid conversation a strong gust flings the bonnet down on my head - catch first; a well crafted spike that heads don't like.
Hindsight says, "if your bonnet catch has hit something hard, it is likely to bend; so check it's in alignment before slamming the bonnet - because you could put a nasty dent in your paintwork".
To cut the long story short, a recovery vehicle and ice-pack later, the 90 is back in the workshop minus an alternator, and we've found a guaranteed exchange unit, plus new pulley and fan at a local auto-electric workshop for £66.
Top bloke, by the name of Andrew, at Autolec in Lowestoft (01502 573 247); this man has everything and a workshop and auto parts collection that would make Aladdin's cave look like a bus stop.
The moral of this tale, if a unit on the engine has suffered damage to moving parts, it is likely that the damage runs deeper than the visible elements.
In this case, because the front bearings had collapsed - the shaft on the alternator had been tapered by the pulley and fan (literally machined as if on a lathe) - and regardless of how tightly you fixed the retaining nut, they were always going to have lateral movement; that caused the nut to be shaved thinner and loose it's bite - increasing the movement of the pulley and fan around the shaft, creating the lovely screeching noise and eventually distorting and cutting the belt.
Get a new unit - it isn't worth your time overhauling the damaged unit, but do make sure it goes to a good home.
