BimmerJeeper

Trying to replace the alternator.
Got stuck on the first step, just like every insane XJ repair, LOL
I can't even tell what size they are.

15mm spins.
Not metric?
Vice grips would not move it

Dremel not an option, since I never figured out how to cut the nut without the stud getting in the way.

00t444e

Remove the alternator from underneath.

BimmerJeeper

No thanks.
Every generation has different issues with alternator removal, and one method does not fit all.
Everyone says for a '98, remove from top.

Dave51

You need 6 point sockets. Try the 14 mm (don't know the size but find the right one). Forget using vise grips. Those bolts are studs so if you mess them up you're going to turn this into a 3 hour job.

Dave51

Wire brush it to get the surface rust off. If that's all metal heat with torch. Once you get the right socket on there work it carefully back and forth after you get it loosened a bit. Add more PB.

Dave51

If you do mess the nut up use a small sharp cold chisel on the side at an angle to get it turning.

00t444e

I removed the one on my 97 from the bottom, the 97 and 98s are identical.

Dave51

I'm looking at my 2000 now (changing the NSS). I don't think it makes a hill o' beans difference top or bottom.

BimmerJeeper

I ended up using fluted bolt extractors.
I snapped off 2 bolts, and then used an impact to get the 3rd one off.
Thank god I have one bolt left to hold the battery.

BimmerJeeper

LOL, I'm already on 3 hours and I have not even touched the alternator
I snapped off 2, but have one left. What would a professional do to repair the broken 2 studs?

I have set aside 20 hours for the project.
Both Sat and Sun.
That's experience, my friends.

Chick-N-Picker

Your experience and mine too.

This should take about 1 hour start to finish.

Me: 7 hours later.

jordan96xj

As a first option, they would try to extract and replace the studs. This may or may not be feasible.

Realistically, they would probably end up grinding off the top of the studs, drilling down through the center of what remains, tap the holes with a common bolt thread size/pitch. Then use some spare bolts and washers to act as battery tray hold-downs.

Dave51

Punch them out with a BFH.

BimmerJeeper

Removal from the top was a dead end, since not one thread mentions the A/C lines removal from the top.

As I sat under the XJ, I wondered if it would ever come out from that frame rail.
What if I couldn't get it out, then I wondered how the hell I would ever reinstall the alternator from such an awkward angle with only 2 arms.

Then I could not even loosen the alternator bolts. Only the bracket bolts.
Said to myself, **** this, and gave up.
I cleaned the the grounds near the alternator and called it a day.
6 hours and I did not even touch the alternator.

Yet again, the XJ is complete nightmare to do even the most basic repair on.
Most idiotic location for an alternator I have ever seen on any car in my lifetime.
Even the serp belt path is a disaster where you can't even see some of the pulleys to route around.

I'll stick to working on my Bimmers, which are easy peasy and simple
I did my Bimmer alternator over the winter, and it was simple compared to this nightmare.
As usual, the Jeeper needs a professional mechanic.

BlueRidgeMark

Pilot error.