Changing alternator on 99 dodge ram truck 5.9L engine...anything I need to do before loosening the alternator bolts?

Hi,

You will be needigng the below;

New alternator

Socket wrench set

Torque wrench

Determine which alternator your Dodge Ram will need. You'll want to be sure the new alternator is compatible with your Ram's engine. A Dodge Ram made after 2001 may be equipped with a 3.7 L, 4.7 L, 5.7 L Hemi V8, 5.9 L Magnum V8, 5.9 L Cummins diesel, 6.7 L Cummins diesel, 8.0 L Magnum or 8.3 L Viper engine.

Disconnect the negative battery cable with a socket wrench. Remove the accessory drive belt and disconnect the wiring harness from the alternator. You will also need to remove the support bracket with a socket wrench for 3.7 L, 4.7 L and 5.7 L engines.

Take the mounting bolts off of the alternator with a socket wrench and remove the alternator assembly.

Install the new alternator assembly. If you have a 3.7 L engine, tighten the horizontal bolts to 42 foot pounds and the vertical bolt to 29 foot pounds with a torque wrench. Torque the long horizontal bolt and vertical bolt to 41 foot pounds and the short horizontal bolt to 55 foot pounds for a 4.7 L engine. Torque the mounting bolts to 30 foot pounds for all other engines.

Connect the wiring harness to the alternator, install the accessory drive belt and connect the negative battery cable.

I hope this helps.

Good luck.

Removal & Installation-tensioner is loosened using a belt tensioner loosening tool on the bolt of the pulley. 5.9L Engine To Remove:
NOTE: This coil is not oil filled. Note spark plug cable original positions before removing.
Coil location - 5.9L Engine (except HDC)

Fig. View of the alternator after removing the splash shield - 2.0L engines



Removal & Install - 2.0L Engines

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   Negative battery cable Alternator jam nut, loosen only Alternator adjustment nut, loosen only Accessory drive splash shield Alternator lower bolt, loosen only Alternator drive belt Alternator field circuit wiring connector, push the RED locking tab to release Battery positive terminal Upper and lower bolts, move alternator off pivot bracket Pivot bracket Alternator

To install:
Install or connect the following:
Alternator Pivot bracket and torque the bolts to 40 ft. lbs. (54 Nm) Alternator, move it onto pivot bracket Alternator field circuit wiring connector, push RED locking tab in until it snaps in place Battery positive terminal Alternator drive belt Tension the drive belt to 100 lbs. (used) or 135 lbs. (new) Alternator adjustment bolt Alternator jam nut and torque nut to 40 ft. lbs. (54 Nm) Alternator mount bolts and torque the bolts to 40 ft. lbs. (54 Nm) Accessory drive splash shield
Negative battery cable

Fig. Alternator mounting-2.4L engine shown



I hope helps with this (remember rated this help) Good luck.

I have the '93 shop manual which describes how to do it with the 3.3L and I have the Haynes that covers the 3.3/3.8L for '96-99 and they read about the same. Let me give you the one from the '93 Chrysler shop manual:
1.Disconnect the battery.
2. Remove the alternator drive belt
3. Loosen, but do not remove, the nut on the support bracket at the exhaust manifold. (this is on the rear of the engine where the bracket is attached to one of the exhaust manifold studs).
4. Remove the alternator tensioner power steering bracket bolt.
5. Remove the tensioner stud nut and the tensioner.
6. Remove the 2 alternator mounting bolts.
7. Remove and position the power steering reservoir from the alternator mounting bracket. Do not remove the hose from the reservoir.
8. Remove the 3 alternator support bracket bolts.
9. Remove intake plenum-to-alternator mounting bracket bolt
10. Remove alternator support bracket.
11. Position alternator and remove alternator wiring.
12. Remove alternator!
Again this is for the 3.3L and is from the '93 van manual but it appears to apply to the 3.8L as well. Installation is the reverse, tighten the mounting bolts to 40 ft-lbs.

Good luck.

inline of air duct (plenum) after air filter

It is behind the alternator. If you disconnect the top alternator bolt and then the lead to the alternator, and loosen the bottom bolt, you can swing the alternator towards the passenger side and see the sensor. You obviously have to remove the serpentine belt to move the alternator.

FIRST OF ALL.TURN OFF RADIO SO YOU WONT LOSE RADIO CODE.FOR THE 2.7L ENGINE.DISCONNECT NEGATIVE BATTERY CABLE.REMOVE THE LOWER PLASTIC SPLASH SHIELD.REMOVE TRANSMISSION COOLER AND POSITION IT ASIDE.REMOVE THE LOWER RADIATOR CROSSMEMBER SUPPORT.LOOSEN BUT DO NOT REMOVE.ADJUSTING T BOLT AND THE PIVOT BOLT.LOOSEN DRIVE BELT ADJUSTING BOLT.REMOVE OR DISCONNECT THE FOLLOWING.DRIVE BELT.REMOVE ALTERNATOR ELECTRICAL WIRES.REMOVE PIVOT BOLT CAREFUL NOT TO LOSE THE SPACER.REMOVE THE ALTERNATOR. NOW THE 3.2L AND 3.5L ENGINES REMOVE THE NEGATIVE BATTERY CABLE.THEN REMOVE THE LOWER MOUNTING BOLT AND PIVIT BOLT.REMOVE DRIVE BELTTENSION BOLT THEN DRIVE BELT.REMOVE BRACKET LOWER MOUNTING BOLT AND PIVOT BOLT.THEN REMOVE THE ALTERNATOR + ALTERNATOR FIELD CIRCUIT PLUG + ALTERNATOR B+ TERMINAL NUT AND WIRE.THEN PUT EVERYTHING BACK VISA VERSA.

No diagram...
The pivot bolt is the long bolt that holds the alternator to the frame.
If you loosen it, the alternator can "swing" with the pivot bolt as its .... well, pivot, or swing center.

The long bolt must be removed completely in order to remove the alternator.

Be sure to doisconnect the negative cable from your battery.

Hope this hleps w/o a diagram.

Remove negative battery cable.
Remove the electrical plug and wireing. Mark them.
Loosen the alternator pivot bolt.
Remove the bolt that attaches the alternator to the adjustment arm.
Rotate the alternator to loosen the drive belt and disengage the belt from the pulley. Be careful that any spacers that are used in mounting are kept with their original bolts. This will make correct reinstallation much easier.
While supporting the alternator remove the pivot bolt.
Remove the alternator from the vehicle.
Do the reverse procedure to install new alternator.

REMOVAL & INSTALLATION

3.3L Engine:

1. Disconnect the battery negative - cable.
2. Disconnect the alternator field circuit plug.
3. Remove the B+ terminal nut and wire.
4. Loosen the adjusting T-bolt, but do not remove it.
5. Loosen the pivot bolt, but do not remove it either.
6. Remove the alternator drive belt.
7. Remove the adjusting T-bolt, pivot bolt, and mounting bolt, be careful not to loose the spacer.
8. Remove the mounting bolt.
9. Remove the spacer & washer
10. Remove alternator.

To install:

1. Attachthe alternator to the support bracket. Tighten all bracket andalternator (except for the wiring nuts) bolts to 40 ft. lbs. (54 Nm).Install the B+ terminal nut and wire and tighten to 75 inch lbs. (9 Nm).
2. Install the drive belt onto the alternator pulley. Make certain that the belt is seated correctly on the pulley.
3. Connect the negative - battery cable.

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3.5L Engine:

1. Disconnect the negative battery cable.
2. Loosen the lower mounting bolt but do not remove it.
3. Loosen the pivot bolt, but do not remove it.
4. Loosen the belt adjusting bolt.
5. Remove the alternator drive belt.
6. Remove the bracket.
7. Remove the lower mounting bolt and pivot bolt.
8. Remove the alternator.
9. Disconnect the alternator field circuit plug.
10. Remove the B+ terminal nut and wire.

To Install:

1. Attach the alternator and bracket to the engine, then tighten the mounting bolts to 40 ft. lbs. (54 Nm).
2. Install the drive belt onto the alternator pulley. Make certain that the belt is seated correctly on the pulley.
3. Install and tighten the B+ terminal nut and wire to 75 inch lbs. (9 Nm) onto the new alternator.
4. Connect the alternator field circuit plug.
5. Connect the negative battery cable.

If you need photos to follow then try this link...
http://www.autozone.com/shopping/repairGuide.htm?pageId=0900c1528006a83e