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TSB 08-007-03

Alternator Mounting Bracket Cracked

Visit Geno's Garage for Truck accessories.

Date: April 4, 2003

Models: 2003 (DR) Ram Truck

NOTE: This bulletin applies to vehicles equipped with a 5.9L 24-Valve Diesel Engine (sales codes ETC, or ETH and built on or before February 13 2003 (MDH 0213XX) and engine serial numbers prior to 67013271.

Overview:
This bulletin involves replacing the alternator support bracket with a revised bracket.

Symptom/Condition:
Vehicle operator may experience an accessory drive belt squeal during normal driving conditions.

Diagnosis:
If the alternator support bracket is cracked, perform the Repair Procedures.

Parts Required:

Qty.	Part No.	Description
1	05086742AB	Bracket, Alternator Support
2	05093136AA	Bolt, Hex Flange Head
2	04429114	Bolt, Hex Flange Head
1	05127471AA	Clip

Repair Procedure:

1. Remove the negative battery cable from both batteries.

2. Remove the drive belt by rotating the belt tensioner clockwise.

3. Loosen the lower alternator support bolt but do not remove.

4. Remove the upper alternator bolt from the support bracket.

5. Rotate the alternator away from the bracket.

6. Disconnect the grid heater harness clip from the alternator support bracket.

7. Remove the 4 bolts securing the alternator support bracket to the cylinder head and discard the bracket and the 4 bolts.

8. Install the replacement alternator support bracket (p/n 05086742AB) utilizing the four new bolls. Position the two studded bolts (p/n 06093136AA) at the front of the bracket as shown in (Fig. 1). Position the two hex head bolts (p/n 04429114) at the rear of the bracket.

9. Tighten all four bracket mounting bolts to 25 Nm (18 ft. lbs.).

10. Attach the alternator wiring harness clip over the lower stud as shown in (Fig. 1).

11. Rotate the alternator back into position and fasten with the upper mounting bolt/nut. Tighten the nut to 41 Nrn (30 ft. lbs-).

12. Tighten the lower alternator mounting bolt to 41 Nm. (30 ft. lbs.).

13. Carefully remove the clip connector from the grid heater harness and discard.

14. Fasten the new push-on wiring clip (p/n 051 27471A) to the grid heater harness using electrical/friction tape. Verify that the clip is aligned with the appropriate mounting stud.

15. Press the wiring clip over the end of the upper mounting bracket stud (Fig. 2).

 

Fig. 1 ALTERNATOR WIRING HARNESS MOUNTING	Fig. 2 GRID HEATER WIRING HARNESS MOUNTING
1 - HEX HEAD BOLTS IN REAR 2 - STUD BOLTS IN FRONT 3 - ALTERNATOR WIRING HARNESS 4 - CLIP OVER LOWER STUD	1 - GRID HEATER WIRING HARNESS 2 - CUP OVER UPPER STUD 3 - ALTERNATOR WIRING HARNESS

16. Install the accessory drive belt.

17. Attach both negative battery cables at the battery.

NOTE. IN THE INTEREST OF CUSTOMER SATISFACTION, RESET THE CLOCK TO THE CORRECT TIME WHEN THE PROCEDURE IS COMPLETE.

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No:  08-06-05-91  Replace Generator Mounting Bracket..................................0.3 Hrs.

Failure Code:  11 - Broken or Cracked

This page was edited on: May 3, 2004