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Update from last weekend...ended up going after the stripped 8mm allen bolt in the upper alternator mount. Just for posterity (since somebody will have this problem eventually), I got it out by cutting a #5 bolt extractor (fine thread) to about half its length, so I could start it in the rounded off hex hole. There wasn't enough space for drilling deeper, much less straight and true. It's recessed, and 3 inches of clearance to work in.
I eventually worked it loose, and then had to use vice grips on the head when it peeked out to work the extractor loose. I stole a replacement bolt from my old NG900 (now sans tensioner).
The rest of the job is also rather painful, the official 'prying the gearbox' approach works to make enough space to withdraw it but I ended up 'pressing' the new alternator in with a bottle jack. Just to note, the reman Bosch I got through Napa for $167. I think eeuro has the same deal. There nearly $100 core on it, too.
The frontpipe bolts were frozen (and not metric, somebody must have busted off the originals sometime back before I owned it) so I just lowered it enough to push aside and support.
I feel a nice sense of victory (also since I'm broke at the moment and couldn't fathom the bill had I not extracted the bolt...the mechanic I asked about it rubbed his eyes and started stammering). Did the brakes, too, Akebonos all around and a good thorough bleed.
However, I think the 9-5 has just crossed my 'everything's packed a little too tight' line for DIY.
--fsik
00 Aero 117K
99 SE LPT 88K
95 900SET 144K (Parts)
posted by 70.235.8...
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