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alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

TD5 alternator change

o.k. alternator decided that it wasn't going to charge battery .... only putting out 11.4 volts, time for a change.

Looking at workshop manual and Haynes manual, what I have to do seems to be

1). Remove viscous fan
2). Remove ancillary drive belt
3). Remove pulley in front of alternator so you can get at torx bolts holding on alternator
4). Disconnect vacuum tubes from alternator
5). Disconnect alternator connections (having disconnected battery)
6). Undo Torx bolts and remove alternator

Simples!

Looking at Haynes manual the pulley in (3) has a strange head on the bolt. What sort of socket do I need to remove it?

Rgds
Alex Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

23rd Aug 2016 2:50pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

Click image to enlarge

23rd Aug 2016 3:31pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

Many thanks for this Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

23rd Aug 2016 3:47pm

dorsetsmith

Member Since: 30 Oct 2011
Location: South West
Posts: 4554

no problem

23rd Aug 2016 3:53pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5858

1999 Defender 110 Td5 SW Caledonian Blue

Are you sure its the Alty? Reason I ask is because I thought mine had gone, but it turned out to be a fuse for the rear lights or rear brake lights that had gone! 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

23rd Aug 2016 5:28pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5858

This was my issue
http://www.defender2.net/forum/topic39823....p;start=15 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

23rd Aug 2016 5:32pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17467

2007 Defender 110 Puma 2.4 DCPU Stornoway Grey

I recently did this on my TD5 Disco. It is awkward rather than difficult, but be aware that none of the fittings (on mine at any rate) are Torx. You will need to disconnect the vacuum line, oil supply, and oil return/air exhaust from the vac pump and, of course, the electrical connection.

The "pulley" you mention is the belt tensioner, just unbolt the whole unit from the block. Unless there's more room on a Defender than a disco also stick a board down the back of the radiator to protect both it and your digits from damage.

My alternator after 200k miles was full of oil from the vacuum pump, and the slip rings had almost worn through. At that mileage though I feel I have had value from it.

23rd Aug 2016 6:20pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

Thanks for this, really useful.I was expecting a Torx simply because the photo in the Haynes manual seemed to show it as one ... I'll find out when I get there. Good tip about the board between you and the radiator. Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Aug 2016 8:34am

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

excossack wrote:
Are you sure its the Alty? Reason I ask is because I thought mine had gone, but it turned out to be a fuse for the rear lights or rear brake lights that had gone!

All my indicator/brake lights are LED and they work. Voltage at alternator 11.4 volts.

Need to wait a bit coz parcelforce 2 working day delivery to campsite in France might have worked if they'd sent it to the right campsite!

Alternator current;y "Lost in France"
... wasn't that a song.

Been sidetracked by state of OSR brakes on Effie the "new" 110, Just bought a pair of rear calipers etc to do tonight
A Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Aug 2016 8:37am

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

excossack wrote:
This was my issue
http://www.defender2.net/forum/topic39823....p;start=15

.... but just in case, I'll check the fuse

Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Aug 2016 8:40am

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

excossack wrote:
Are you sure its the Alty? Reason I ask is because I thought mine had gone, but it turned out to be a fuse for the rear lights or rear brake lights that had gone!

Slightly red faced here

Yup no brake lights working
Put new fuse in and it blows immediately when you switch ignition on. Time to look at wiring diagram methinks

A Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Aug 2016 5:26pm

blackwolf

Member Since: 03 Nov 2009
Location: South West England
Posts: 17467

Interesting that the Haynes manual does indeed show a Torx bolt, looks about T25. Perhaps mine has a non-original bolt, or I'm having a senior moment!

24th Aug 2016 6:53pm

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

alexatnd wrote:
excossack wrote:
Are you sure its the Alty? Reason I ask is because I thought mine had gone, but it turned out to be a fuse for the rear lights or rear brake lights that had gone!

Slightly red faced here

Yup no brake lights working
Put new fuse in and it blows immediately when you switch ignition on. Time to look at wiring diagram methinks

A

well, it ain't the rear light cluster, can;t see how it would b the brake switch. Think reversing light goes through the same fulse though. Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

24th Aug 2016 9:12pm

excossack

Member Since: 22 Feb 2012
Location: North West
Posts: 5858

Good luck chasing the fault! 1999 Defender TD5 110

Regards
John M0VAZ
Econet Station 48 no clock

25th Aug 2016 7:51am

alexatnd

Member Since: 19 May 2015
Location: Yorkshire
Posts: 280

Current thought is that its the reversing light switch, its a metal case and has +ve going in and to the light so possibility of a short Santa - 1977 Series 3 - new chassis, tub, disc brakes,SU Carb
Gertie - 1999 110 TD5 - like a Phoenix from the ashes back on road... almost
Effie - 2004 110 TD5 County

25th Aug 2016 10:20am

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