Installing Alternator Problem, any tips or tricks?

[SubaruWRXMike]

So I removed my alternator and I am trying to install the one I bought from Advance Auto Parts down the street. It looks the same with all the mounting parts in the same place. I am having a lot of trouble getting the alternator into the pivot mounting bracket. When I removed the alternator, I really had to wiggle and pull it out really hard, I think the bracket might be warped or something, but now I'm trying to get it back in but it won't go in. Any tips or tricks for getting a very tight fitting alternator in? Do I go from the top/bottom? Keep pivoting it or should I wiggle it side to side. I am stranded wtihout the alternator. Really need some help. This is for a 1996 Toyota Carmry, 2.2L 5SFE (or something like that).

[Mister_Perkins]

Lay it over top of the bracket and tap it down with a rubber mallet. Make sure its lined up straight before tapping it.

[ghettosled]

what if you filed/grinded the edge slightly (bevel/chamfer the edge) to help slide it together?

[Mister_Perkins]

^ could do that too.

I just tapped my alternator back in place after I finished my timing change.

I'm just laaaazzzzyyyyy sometimes. lol

[Mike Gerber]

I had this problem years ago with an 86 Camry. It's still the same design on the generation 3 you have. (I have a 94.) I scratched my head for a while until I figured out a solution. Get a hex bolt slightly smaller overall than the space between the 2 ears of the bracket. There is a little bushing inside one side of those ears that is forced in to the old and now new alternator. Put a nut on the bolt and screw it on to the bolt past the end of the bolt. Now place the bolt and nut assembly between the 2 ears and with 2 wrenches start turning the nut off. Go a little at a time and then try to see if the alternator now fits in. This should push that bushing back in to the ear on that side. Think of this a a reverse vice. Some penetrating oil on the side with the bushing should also help. This is what worked for me.

Mike

[SubaruWRXMike]

Thanks for the suggestion, I bought a rubber mallet and it's still not budging, going to buy a file now. Any particular type for this job?

[SexieWASD]

follow mike's advice, that bushing moves.

[rusty9]

Use a bigger hammer. I prefer the 4lb sledge. Or bring it back and try another alternator if you dont want to grind it down. I swear whoever makes OEM replacements casts them about 2mm too big for that bracket.

[SubaruWRXMike]

Thanks everyone so much for all your help. I don't know what I would do without toyota nation. I filed down the metal part and it worked. It took me the whole day and three trips to Lowe's hardware store. I'm in school in another state and don't have any tools with me. Luckily Advance Auto Parts and Lowe's were within walking distance. I would have been pretty screwed without the car. Thanks everyone again, and if any of you live in Miami I'll drop off a 6 pack of beer for you.

[giantjoebot]

Thank you so much. The bolt did the trick. I was fighting with it for an hour, and figured there had to be a trick to it. This was on a 91 pickup.

[Mister_Perkins]

ya know .. I was doing this the other day and I realized that you dont even need to force the alternator in there with a Hammer. If you look while the alternator is out, the bushing gets pulled past the Ear on the bracket. Grab a hammer and a punch or something hard to hit against that bushing. Place it on the inside side where the alternator normally sits and hit towards the passenger side. The bushing will go flush, and the alternator will fall inside the bracket.

I've always just whacked them into place, but this method of using a punch is WAY easier. You can even get it without using a punch. Just using the hammer.

Heres a picture of what im talkin about