Alternator question ! (PIC) Nut on back of alternator does not loosen !

[5ABI VT]

Tried loosening the but and heart a faint tick and the harness started to rotate with the nut. I marked the tip of the bolt and it's rotating with the nut.

Everything is right and secure so I can leave it but I'm thinking to sort it out now while it's all accessible.

Does the alternator need to come apart to fix this ? This is the nut..

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/0C31CF2C-B8C9-483F-9CD7-9E3A9711D88D_zpsahw2eypg.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/0C31CF2C-B8C9-483F-9CD7-9E3A9711D88D_zpsahw2eypg.jpg.html)

Thanks on advance :)

[Franke]

Yes. The head of that bolt is square inside the alternator. Looking at your pic I see a cracked through hole bolt insulator which will also need to be replaced so that you don't get a short from battery to ground. I bet that insulator cracked when the bolt spun. I would replace these parts as soon as possible.

[GOLDCYLON]

Yep your going to need to open it up as its spinning inside

[5ABI VT]

I would have to guess someone overtightened it before me. That's exactly how it was before I started. all I did was put a socket on and the bolt and socket both rotate so I cant loosen it.

Looks like Ill be getting a lesson on rebuilding alternators too :dancing

[5ABI VT]

Yep your going to need to open it up as its spinning inside

Does it matter that everything is still tight the way it is? I was hoping to get to putting the plenum back together and now this.. :/

Basically I was loosening it because I was going to add wire to go to the battery plus another ground off the case to the battery. A car audio upgrade that pretty much only has benefits so I figured why not (big 3/4 upgrade)

[BennieC.]

Try to loosen it with a 3/8 impact gun if available.

[Franke]

I would say for peace of mind and safety sake that I would replace those parts especially that insulator. That insulator cannot be substituted for by anything else but the right one.

[5ABI VT]

Appreciate the Input. Didn't think much of the cracked plastic but I watched a few rebuild videos at work and didn't realize they sell every little piece for these. I'll be pulling it apart shortly when I get home and I'll look to replace that piece and do it right.

Is there a replacement alternator that is considered an upgrade to the original ? Not a fan of rebuilt alternators as they're sometimes hit or miss in my experience.

[RICHARD TILL]

I`d be concerned about the wire that is attached to the head of the bolt. Its actually a simple job to repair. Check you-tube on GM alternator rebuilding.

[Z51JEFF]

Hey Mike these are pretty easy to work on,the biggest challenge is getting the brush holder straightened out.There is a hole in the brush holder and this is what holds the brushes back while the armature goes back in the housing.Send me a P.M. and I can give you some tips.

[secondchance]

When repaired get a replacement rubber boot Dynomite found. Pic shows original piece cried up and broken off.
http://www.zr1.net/forum/showthread.php?t=23045&highlight=alternator+boot

[5ABI VT]

I got it all apart in about 5 minutes quite simple really. Jeff I'll pm about the springs/magnets I can picture what needs to be fine I think. Ill post up photos in a few minutes.

The bolt has a square on it but it wasn't Inside the casing far enough to prevent from turning. The insulator looks like it definitely needs replacing too. I also have questions in the magnet wear.. Something I could replace or would a rebuilt /new alt be a good idea ?

Pics coming .. And thx everyone for the input :)

[5ABI VT]

Opened up easily enough
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B0272551-EAAF-4469-8EEE-8BBB4B52B4B5_zpsvepyxndp.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/B0272551-EAAF-4469-8EEE-8BBB4B52B4B5_zpsvepyxndp.jpg.html)
Electrical contact cleaner or?? To clean up inside ?

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/0D89C7DF-9E54-427D-BF00-21C8E6CDF2BB_zpsir1ix4tl.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/0D89C7DF-9E54-427D-BF00-21C8E6CDF2BB_zpsir1ix4tl.jpg.html)

Brushes .. Looking worn ?
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/0C910E2B-854B-4ABA-86BF-978E5E3C7542_zpssphzuf72.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/0C910E2B-854B-4ABA-86BF-978E5E3C7542_zpssphzuf72.jpg.html)

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/20937557-3194-46AD-B980-1AB564CD0A38_zpsrmaxdp3c.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/20937557-3194-46AD-B980-1AB564CD0A38_zpsrmaxdp3c.jpg.html)

Insulator I take it.
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BD2F8B98-7F96-43DD-8900-82CFC8ECF53E_zpsaqybotij.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/BD2F8B98-7F96-43DD-8900-82CFC8ECF53E_zpsaqybotij.jpg.html)

Bolt doesn't go inside far enough .. Odd .. Possible fail rebuild ?

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/813C43B3-CA54-4F41-9E4D-3599E7168923_zpsn3mxye4r.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Plenum%20and%20IH%20pull%20%20porting/813C43B3-CA54-4F41-9E4D-3599E7168923_zpsn3mxye4r.jpg.html)

[5ABI VT]

I noticed a little fraying of the wire holding one of the brushes. Should it be ok to re-use or should i replace it?

Anyone have the alternator model number for a 94? I see online theres an early and late cs144 so Im not sure which parts to order for it.:confused:

[WVZR-1]

I noticed a little fraying of the wire holding one of the brushes. Should it be ok to re-use or should i replace it?

Anyone have the alternator model number for a 94? I see online theres an early and late cs144 so Im not sure which parts to order for it.:confused:

Just do your parts "local". GM 1975471 or an equivalent would be a correct terminal package, GM 1989702 for a brush holder if you wanted. If your alternator is original it should be cast 10479904, use that number when referencing any parts. The LT5 CS144 is the earlier model generally when referencing and in '90 there were internal differences for some also.

[Z51JEFF]

Why you have this apart you might want to blast the cases with walnut shells.If you do blast don't use anything that is abrasive,you just want to cut the corosion and dirt stains on the cases.

[-=Jeff=-]

I bought my replacement rotor from here:
http://store.alternatorparts.com/gm-delco-cs144-series-parts.aspx

I still need a regulator and rectifier for it.. I broke (one or both) when I tested it with a bad rotor

[5ABI VT]

Thanks !! I'll look Into a brush kit and will look into replacing the entire alternator internals myself.

I contacted mechman alternators and they said they didn't make an alternator for the zr-1. Is the alternator different because of the housing /bracket vs other cs 144 alternators?

[5ABI VT]

Spoke with a few manufacturers of billet alternators but they all say the same thing : looks like a std cs 144 but they don't list it for the zr-1.

Anyone know what the differences are? Is it the casing /mounting dimensions or I'm thinking possibly the pulley size ?

Here's a few photos I wanted to share and get input if possible

Cleaned up this part I forget the name but on YouTube they said to sand it lightly. Bearing is smooth and does say japan on it.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/C74BF437-A9BC-4F2C-BB38-E692E5F43240_zpsqedjrgnv.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/C74BF437-A9BC-4F2C-BB38-E692E5F43240_zpsqedjrgnv.jpg.html)

Someone enlightened me on Facebook that this piece looks too dark and should be replaced. I believe it's the stator ? I did google tons of pics and have seen lots if bright copper but a fair share of darker copper ones ??

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/ECB8B462-C25A-4D99-AD56-4BDA14361268_zpsnrx6pxxv.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/ECB8B462-C25A-4D99-AD56-4BDA14361268_zpsnrx6pxxv.jpg.html)

Back housing with a new ground bolt and insulator
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/60543850-5F3C-45FD-90F4-614BB2EA25E0_zpsytrvyqqe.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/60543850-5F3C-45FD-90F4-614BB2EA25E0_zpsytrvyqqe.jpg.html)

Pic of the old brush on the right. The alt shoppe I got the insulator from had a used looking brush holder with new magnets he gave me. I did swap it in last night and it wasn't difficult . I did order a new gm replacement my dealer will have it tomorrow.

http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/FFEF1AFF-6552-4DB7-AB66-D904B690408E_zpsdhkpaayd.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/FFEF1AFF-6552-4DB7-AB66-D904B690408E_zpsdhkpaayd.jpg.html)

Part number
http://i1207.photobucket.com/albums/bb463/Emm3Speed/ZR-1%20Clutch%20flywheel%20install/D1FDBAFB-BC5C-4980-9D34-58D290727E22_zps4ozliipu.jpg (http://s1207.photobucket.com/user/Emm3Speed/media/ZR-1%20Clutch%20flywheel%20install/D1FDBAFB-BC5C-4980-9D34-58D290727E22_zps4ozliipu.jpg.html)

[WVZR-1]

The alternator certainly appears to be the original with the correct production number, a date code of 1083 (4/18/93), if you had no charging issues previously I don't believe I'd have any trouble using it "as is", the stator I don't believe is as great an issue as you've been told.

There are remans available and there are vendors that do higher amp units that are direct fit. Pulley swaps are required for some.

[5ABI VT]

Thanks for the input ! Very cool about the production date. Im not one for orginal stuff but I don't think Ill give this alt back as a core when I replace it lol :) Tomorrow I get the new old stock brush kit my local dealer was able to get and Ill reassemble it. Ill be making new power and ground wires to add on to it tonight. Then.. this top end is ready get back together !! Sucks though the next few days is forecasting some light snow (<1 cm) but if I can get it done.. it may give a nice opportunity for some photos !

[WVZR-1]

You might consider after reassembly to have the shop check it on the bench to confirm operation. There's no obvious reason for concern but it certainly might be wise.

[5ABI VT]

Not a bad idea I'll zip by the alt rebuild guys I deal with and ask on the way to work. Definitely won't be leaving it though as I'm sure I'll come back and they'll say it needed everything replaced ;)

[jrd1990zr1]

I had a similar problem this year at Carlisle. When driving to the hotel on Thursday night thought I smelled burning paper, but the smell went away. Drove to Carlisle Friday everything was good. Left carlilse for the hotel about 2 miles from the show field the ammeter on dash went to 8. Got to the Hotel shut the car off, battery was dead, alternator was VERY hot.

Thanks to the help of Jim Voter, MysticZR1 and a few others we replaced the alternator by flashlight in the parking lot. Major problem was that same electrical bolt would spin, not loosen. We ended up having it break off.

Long story short the diodes are attached to the other side of that bolt and when they fried the bolt spins.

My thanks to all that helped me out, replacing the alternator without pulling the plenum is a bear to do!

Have a shop check out your alternator befor you re-install it. :cheers: