Alternator bushings - getting them seated

[Pablo M]

Among the many things I’m doing while I have a garage I’m replacing the alternator bushings, given the alternator was crooked in the upper mount lol. 
 

I got the short one in but it was very difficult. It needed a lot of coaxing with a hammer. 
The long one is fighting me. I tried getting the two bushings in first, got them seated, but then counldnt get the insert in at all. Ended up pulling it back out with the bushing. So I tried getting it in with bushing again. Lots of beating on it and this is as far as I got it in. I’m afraid of breaking the alternator ear. 
 

Im

going to try putting it in a vise to squeeze it together. 
many advice for getting these in? 
 

 

 

Also note the insulation around the plug in back crumbled in my hands. I looked at it sideways and it came apart. Is this important to replace (or even possible)? 
 

 

 

thank you! 

[stephers]

Put the bushing in first, then press the center sleeve in    They are tight   use lots of lube     I always found that getting the washer and the circlip in more of a headache, ended up buying a bunch of shiner shims to use instead of the washer

 

Use your vice and get someone to help you 3 hand here work much better.

 

Thanks, Rick

[Buckeye]

Put fat bolt thru the bushing with a nut and attache it to your electric drill (that is your lathe now) then use emery cloth/ sand paper and turn it down just a bit. 

[tech71]

Dont hammer it! Use a vise or C clamp.

Put a little lube on it. 

Typical "almost fits" scenario with the Urethane bushings, I hate them.

Sometimes "better" is worse.

Got some fitting to do, got coarse sandpaper? Get comfy.

Make sure the Alt bore is clean and sand it out too.

Once those beasties are correctly, fitted make sure the bolt will go through.

Umm, that alternator looks kinda high milage, have you considered a replacement or maybe an upgrade?

Edited February 3 by tech71

[Mike Self]

I had the same problem installing that bushing, even after filing down the exterior a bit.  Finally got it in by lubing it with silicone grease (dish soap will also work) and squeezing in with a large vise.  Funny thing is that I don't remember having much trouble at ll when I did the same urethane bushings on my '73 many years ago.  IIRC they slid right in with no problem.

 

mike

[Pablo M]

4 hours ago, stephers said:

Put the bushing in first, then press the center sleeve in    They are tight   use lots of lube     I always found that getting the washer and the circlip in more of a headache, ended up buying a bunch of shiner shims to use instead of the washer

 

Use your vice and get someone to help you 3 hand here work much better.

 

Thanks, Rick

That worked fine for the smaller (shorter) bushing. The long one didn’t work like that. The center sleeve polished out the bottom bushing. I ended up pulling it back out with the top bushing. 
min trying the vise, but forgot lube! 
 

 

3 hours ago, tech71 said:

Dont hammer it! Use a vise or C clamp.

Put a little lube on it. 

Typical "almost fits" scenario with the Urethane bushings, I hate them.

Sometimes "better" is worse.

Got some fitting to do, got coarse sandpaper? Get comfy.

Make sure the Alt bore is clean and sand it out too.

Once those beasties are correctly, fitted make sure the bolt will go through.

Umm, that alternator looks kinda high milage, have you considered a replacement or maybe an upgrade?

I put urethane bushings throughout the suspension and didn’t have these issues. But I knew going in they were a tight fit. 
I did sand the bore, by hand, so it was clean of the remnants from old bushing. 
yeah, alternator looks original. I have receipts on the car back to early 1976 and no alternator replacement in any paperwork I have. So could be original. Also, I may not have all the paperwork. 

It’s working so I’ll keep it for now. Plenty of other things on my list. If it fails I’ll take care of it then. Also, this is after I cleaned it lol. 
oof. 
 

52 minutes ago, Mike Self said:

I had the same problem installing that bushing, even after filing down the exterior a bit.  Finally got it in by lubing it with silicone grease (dish soap will also work) and squeezing in with a large vise.  Funny thing is that I don't remember having much trouble at ll when I did the same urethane bushings on my '73 many years ago.  IIRC they slid right in with no problem.

 

mike

I forgot lube. Damn sleep deprivation. May be too late to get some in there. I may try some dish soap around it. Not sure there’s any space for it to capillary action into space lol. 
 

 

Thanks everyone. 

 

[Pablo M]

Almost got it all the way in. 
I had to throw a big wrench on the end to get enough leverage. Older Craftsman. Still slides through though lol. 

 

almost tempted to shave off a bit of the bushing at this point. Or spend all of tomorrow to take it back out and try again. 

['76mintgrün'02]

I agree with Buckeye.  Make the bushing smaller, so it fits the hole.  Someone wasn't paying attention when they selected that bushing.  It is too big. 

 

You could also put a slight chamfer on the edge of the hole, so it doesn't dig into the bushing.

 

 

[tech71]

That suckers clearly too large in Dia, even if you get it  rammed in there the inner sleeve will never go in without ( at the very least) reaming. 

seriously dude, all this time, effort and frustration for an ancient, grody original 45 amp alternator seems like an exercise in futility…

Edited February 4 by tech71

[Mike Self]

If you have a drill press--or even an electric drill you can hold down in a vise or with clamps...

 

First, measure the ID of the hole on the alternator, then the OD of the offending bushing so you'll know how much material to remove. Then...

 

Take the bushing and imprison it between two nuts and washers on a long bolt.  Chuck the bolt in your drill (press), turn it on and either hold a coarse metal file or 80 grit sandpaper against it, checking periodically to see how much material you've removed.  When you have it just a tiny bit smaller than the receiving hole, chamfer the inserting end of the bushing, lube it up and insert.  Even if it's a little loose when going in, it'll be compressed  between the washers and circlips and will be nice and tight once reassembled.

 

mike

[Pablo M]

On 2/3/2024 at 3:29 PM, Mike Self said:

If you have a drill press--or even an electric drill you can hold down in a vise or with clamps...

 

First, measure the ID of the hole on the alternator, then the OD of the offending bushing so you'll know how much material to remove. Then...

 

Take the bushing and imprison it between two nuts and washers on a long bolt.  Chuck the bolt in your drill (press), turn it on and either hold a coarse metal file or 80 grit sandpaper against it, checking periodically to see how much material you've removed.  When you have it just a tiny bit smaller than the receiving hole, chamfer the inserting end of the bushing, lube it up and insert.  Even if it's a little loose when going in, it'll be compressed  between the washers and circlips and will be nice and tight once reassembled.

 

mike

I had to reorder the bushing set having destroyed the one last one I tried to force in. Arrived the other day (thanks @BLUNT for fast shipping!). Did exactly as you described: used Dremel as a lathe to remove outer material, with 100 grit, slowly until it ‘just’ fit. Then took sanding drum on Dremel to inside until the insert ‘just’ fit as well. Did same for bushing already in. All together now and will go back in tomorrow. 
Thanks for the help everyone! 

[James Laray]

I have this same issue.  I ordered urethane bushings from BavAuto years ago (when they were still around) for my 69 and they were to big.  Thought it was a bum order, I ordered another set from somewhere else.  Too big.   I finally configured some traditional rubber ones which I now need to replace.   Guess I will pull out the red urethanes and follow these recommendations.  Thanks