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Old 01-19-2023, 10:23 AM #1
Danger Danger is offline
Join Date: Nov 2013
Location: Middle Tennessee
Posts: 36
Danger is on a distinguished road
Danger Danger is offline
Join Date: Nov 2013
Location: Middle Tennessee
Posts: 36
Danger is on a distinguished road
2005 V8 Alternator Diagnosis and Fast Replacement Instructions

A few months ago I started having sporadic power steering fluid drips and leaks from the lines between the pump/reservoir and the steering rack. As I replaced one line another would leak, etc. At some point the pump started whining, so I replaced it (coming up on 200k miles). I figured that it had pulled in air some time during these leaks. Apparently some of the PS fluid (AT fluid) spilled onto the alternator because I would hear an intermittent whine and the battery light starting coming on once in a while. Here is my method for ~1.5 hour battery replacement with vehicle on the ground, and without dealing with wheel removal or sway bar end links:
  1. Remove battery connections
  2. Remove 3 bolts on the coolant reservoir and flip it up out of the way
  3. Use breaker bar to press tensioner and slide off belt
  4. Put socket extension through PS pulley and loosen nut
  5. Slide off PS pulley
  6. From Pass. Side remove 10mm nut/wire and electrical connector from alternator (I did not remove wheel or sway bar link)
  7. Remove skid plate
  8. Remove 2 nuts and one bolt from front of alternator
  9. Remove 1 nut holding wire loom from bottom of alternator
  10. Remove coolant line bolt to give wiggle room for alternator
  11. Remove 4 sway bar 17mm bolts and flip it forward onto a jack stand
  12. Remove alternator toward front/bottom of vehicle and reverse for install

After installing I started and idled the engine for a while. It was much quieter, I must have not noticed the gradual increase in bearing noise from the alternator.

After about 10 minutes of idling the battery light came on again. I shut it off and charged the battery. I ASSUMED that the Alt not charging had permanently damaged the old battery at some point. I drove 10 minutes to the Auto Parts store and it did not stall or stumble. I swapped batteries in the parking lot. With the new battery installed I drove on the highway for 15 miles. The battery light flickered a few times then stayed off. I am assuming that the battery at the auto parts store did not have a full charge sitting on the shelf.

After driving for a while with no battery light showing, I got home and checked the voltage at the battery terminals with the engine idling and got 13.9V which seems good. I kept my old Denso Alternator and am waiting on the rebuild parts so I can tear it down. I believe it is worth more than the $40 core charge.
2014 SR5 4x4 - Stock
*SOLD 2005 Toyota 4Runner Limited - 4WD/V8/Toytec 2" Springs/Bilstein 5100

Last edited by Danger; 01-19-2023 at 10:29 AM.
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alternator , bar , battery , light , remove

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