'06 300 Touring alternator removal
 

My son is off at college with an '06 300 Touring edition and has an alternator that is making an unpleasant noise.


He initially took the car to a Chrysler Dealership for recall work and a quick diagnosis of the "unpleasant noise". The Dealer determined the noise was from one of the pulleys (inline with the alternator) and the alternator itself.
The dealership wanted over $700 to fix everything.


I bought the alternator, pulley and serpentine belt for less than $200 and figured I could make the 5 hour drive to my son's college town and work on the vehicle in a friends heated garage.


The pulley removal and new install took a couple of minutes.
With the car jacked up, I was quickly able to loosen the two bolts on the bottom side of the alternator.


We struggled for hours trying to loosen the upper bolt (the LONG bolt that is somewhat hidden by the alternator bracket). My friend could probably win some Strong Man Competitions, but you could only see the entire motor being raised as he tried to loosen that bolt. We got close to "rounding" the head of the bolt, but the bolt head is still in somewhat good shape.


What are the magic words I need to utter to remove that top bolt?


It's a steel bolt that is fused inside aluminum. If you are familiar with this part, you will know that there is no place to squirt penetrating oil.


Please! Does anyone have any tips/tricks or advice to remove that top bolt.


Thanks

are you talking about this bolt on the top of the alternator? if so, PB blaster at the head and in between the alternator mount and the engine block. let it set for a little while. if that don't work, then get a micro torch and apply heat. It should only be torqued to about 35 ft lbs but might have some blue or red loctite on it from the factory.

https://dl.dropbox.com/s/t2uls5zmotq...0bolt.JPG?dl=0

Thank you very much for the reply.


I believe you are referring to the same bolt, except my son has the 2006 300 Touring Edition (six banger). There is a bracket that runs from the alternator to the engine block and it hides the bolt head.


It's a tough place to maneuver because there is a "Block with 6 fuel lines" opposite of where you would put a socket on the (15mm?) bolt head.


The bracket itself is very limiting and the so called "block" does you no favors.


I would have loved to throw my biggest ratchet and a breaker bar at the bolt, but there is limited access.


I will buy some PB and have a torch handy.


Thanks again for you help!

Same problem