Quote:
Originally Posted by sam o nela
Thanks guys...regarding banging the alt...
Yeah on my 2.5 its always been like that...in fact you can see on the video just how much force it took to get the alternator in there!!
I was surprised how easily it went in on the 2.7 parts car....thus I threw in the sentence on the writeup about "some people getting lucky..." 
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Well mine started to go again, I could do this blindfolded now. It was from my parts car, bat light started to occasionally flicker at low revs and high load. After I'm guessing a year and a half this time. Put my brand new re-manned Auto zone one I have been hanging on while my parts car one was in. Lets see how this one goes... I'm going to take apart my parts one and try to replace the brushes, I don't think it's a diode problem this time (most of mine failed that way), its just getting weak.
I just wanted to add a simple suggestion to your DIY because I don't like using any kind of hammer especially on any electric part rubber or not. I ran into the fit problem on the old parts car one and the one i put in today where the front screw holds the unit in place. I simply took a file and filed a small amount of the high spot on the circular area where the screw goes through on the alternator. The unit drops right in then with no problems - no effort.
What is the deal with these alternators? I think that is number 5 for me. Pretty well averaging one per year. The only good part is it's in a really easy to get to spot. My friend had an Elantra, same deal with that car. It eats alternators.