How do you replace the alternator on a 1973 VW Beetle?

Answer 1

1 Disconnect the battery. 2 Unplugg the three electrical wires.(one may have a bolt) 3 Loosen the three support bolt. 4 Lift the alternater slightly with a crowbar to release the tension on the belt. 5 Remove the belt. 6 Remove the three support bolt and the alternater should come right off. If the engine is in the car..... after step 2 insert the following 2a. Remove Carburator and Intake manifolds where connected to the heads. This also means you remove the heater pipe and the rubber fittings. Make sure nothing falls into the resulting intakes in the heads after removing the intake pipes. Now loosen the alternator from the alternator stand and remove the belt. Also. remove 4 nuts that hold the cooling fan assembly(still connected to the alternator) to the doghouse. OK everything is loose now. 2b. Loosen the screws at the base of the doghouse- one on each side Maybe a short screwdriver will do it, maybe a wrench. 2c. Get a piece of wood and get ready.. now lift the doghouse and shove the wood in to raise the doghouse a couple inches. 2d. Loosen the nuts at the base of the generator stand and remove stand. Now everything falls out. 3. The alternator comes out with the cooling fan attached in the rear; this needs to be removed and reused, as does the inner pully. You will need a 36mm socket for the fan end and a flat screwdriver jammed between the alternator housing and inner pully on the other end to successfully break it free. You may also need a gear puller if the fan and inner pully do not agree with coming off the alternator shaft once the nuts are removed. Also be aware that there is a Woodruff key on both ends which will likely fall off; they must be reused (it prevents the fan/pully from spinning on the shaft.) (Note: If you end up buying a large 36mm socket, it can also used to remove the rear wheel drums when doing brake/bearing replacement. You'll probably find it needs a large 3/4" drive, but a 3/4" to 1/2" adapter will do, assuming you have a 1/2" ratchet or breaker bar.) Its a frustrating job that will take you several hours, but very satisfying when you realize how much money you saved doing it yourself, and hey, You Did IT!