[cpedrich]

Hi,
I am getting ready to replace the alternator bracket for the third time. Was told it might be due to the worn motor mounts. Replaced the mounts two weeks ago as well as replaced the bracket at the same time. Bracket just broke yesterday. I replaced the tensioner about a month ago. When running, everything looks aligned with no wobbling as far as I can tell. Wondering if anyone has had this problem. Don't know if the tensioner is able to be adjusted. Any help would be greatly appreciated.
Thanks!

 

[New Dad New Van]

Suggest only OEM Honda belt and components be used. Use correct torque on the bracket bolts. Search on "alternator bracket" for more info.

 

[cpedrich]

Went to the Honda parts department and asked if they have ever heard of the bracket breaking this many times. He said that he has not. I asked if there is any kind of warranty on the part. He saw when I bought the last one and said that they would warranty it for me. He did not charge for the third bracket. If this happens to anyone else, do ask for some kind of warranty. I did buy a Honda belt this time. Hopefully, this will work. I will follow up and post the results after a few weeks. Thanks!!!

 

[EE4Life]

Here is information from Honda on this issue.

See page 2 of the May 2004 Honda Service News:

Broken Alternator Bracket or Bracket Mounting Bolt
http://www.urvi.net/forumfiles/SN/A040500.pdf
http://techinfo.honda.com/Rjanisis/pubs/SN/A040500.PDF

Honda Tech Line Summary Article:

Broken alternator bracket or lower mounting bolt
http://www.urvi.net/forumfiles/SB/ATS040402.PDF
http://techinfo.honda.com/Rjanisis/pubs/TS/ATS040402.PDF

 

[0dyfamily]

The above .pdf linked documents are so true. After my wife hit another vehicle with her 2002 EX, the body shop had to remove and re-install the alternator to facilitate other work. Well, they did not tighten the lower bolt or bracket bolts to the proper torque. Lower bolt broke, and that upper bracket fractured. I installed new parts, same identical breakages happened yet again because I could not fit a torque wrench in on that lower bolt.

Cannot remember what I did in terms of an extension to make that torque wrench fit (crow's foot? Can't recall), but I eventually did get the exact torque setting on that lower bolt and the bracket bolts, and it has now held up well for many years. I can't believe I could have been that far off in applied torque by just using a plain box end wrench, but this is one of those fastener sets that truly needs the exact specified torque on all fasteners. Too little or too much, and they will not hold up.

OF

 

[cpedrich]

Well, after only a few days, the battery light comes on and off at certain times as if the alternator is not charging. Stays on for about ten seconds at the most, then goes off. This happened before the bracket broke the past times. This is so frustrating. Got the Honda belt on correctly. The only thing that I can think of after reading all the posts is that the torque may be off. I really can not see how that could be such a problem. I could not find my old torque wrench. Does Autozone or places like that let you borrow real quick to use in their parking lot? How or what has been used to get to the mounting bolt? I honestly can not think of anything else that would keep causing this. I really do not want to take it in since it does not happen every time it is driven. Had the alternator tested, and it was working fine.

 

[bruce2]

Make sure you have good grounds.

 

[armik123]

You might want to try something like http://www.powersportsplace.com/parts/ptm-pp2783-12/media/images, of course, remember that attaching it to your torque wrench will change your calibration, so you have to recalculate with consideration to the attachement length

 

[cpedrich]

Just a follow up. It dawned on me that the lower bolt was not tight. Tightened it up, and not problems since. Duh.
Thanks everyone!

 

[mrfixitmyself]

I had the same issue with my '02. The original bracket broke at around 160,00 mi., but it had partially broken/split on one side earlier (it had rusted at the break - if you've seen one, you know what I mean) and later the other side. I replaced the bracket with an OEM part, but, like cpedrich, I failed to tighten the lower bolt! Argh! However, I am not sure what caused the original to break. The tensioner has never been replaced, and something was making a shrill sound even after I replaced the bracket, so something is worn. I do not believe the noise was coming from the belt. What tool do I need to get the tensioner bolt out? My 3/4" drive socket handle is not strong enough, and the space is narrow.

Any thoughts/suggestions much appreciated.

 

[mrfixitmyself]

I had the same issue with my '02. The original bracket broke at around 160,00 mi., but it had partially broken/split on one side earlier (it had rusted at the break - if you've seen one, you know what I mean) and later the other side. I replaced the bracket with an OEM part, but, like cpedrich, I failed to tighten the lower bolt! Argh! However, I am not sure what caused the original to break. The tensioner has never been replaced, and something was making a shrill sound even after I replaced the bracket, so something is worn. I do not believe the noise was coming from the belt. What tool do I need to get the tensioner bolt out? My 3/4" drive socket handle is not strong enough, and the space is narrow.

Any thoughts/suggestions will be much appreciated.

 

[Ron777]

In my case, the lower bolt on the alternator could not be torqued to the necessary 33FT-LBS and this WILL cause the upper alternator bracket ("stay") to break over time.

Need to remove the belt tensioner (use an offset 17mm box wrench to access -- answering the above question) to properly access the lower alternator bolt. Proper tension is important here -- to eliminate the alternator vibration that causes the mount to break, and yet not damage the soft aluminum threads in the block.

 

[0dyfamily]

In my case, the lower bolt on the alternator could not be torqued to the necessary 33FT-LBS and this WILL cause the upper alternator bracket ("stay") to break over time.

Need to remove the belt tensioner (use an offset 17mm box wrench to access -- answering the above question) to properly access the lower alternator bolt. Proper tension is important here -- to eliminate the alternator vibration that causes the mount to break, and yet not damage the soft aluminum threads in the block.

Ron, we'd wished we'd this information the first and second times we broke this stuff. This post is THE whole answer in a nutshell.

OF

 

[Ron777]

Haha....thanks OF -- I had to learn this the hard way, hoping to spare the fellow forum members from a LOT of headache.

(The parts guy at our local Honda says that our generation (99-04) was prone to this alternator bracket failing often, but did not know the cause.)

 

[rolandathegypsy]

My question to this thread, seeing as the bracket breaks I am guessing because of cheap pot metal. Has anyone manufactured one themselves out of scrap angle iron? How hard can it be to transfer the design on angle iron and cut it?

 

[02ody02]

After my alternator was replaced, the bracket broke a couple weeks later. Picture in this thread. http://www.odyclub.com/forums/24-19...rake-battery-opened-door-lights-always-2.html

 

[Beth Popeye]

Hi,
I am getting ready to replace the alternator bracket for the third time. Was told it might be due to the worn motor mounts. Replaced the mounts two weeks ago as well as replaced the bracket at the same time. Bracket just broke yesterday. I replaced the tensioner about a month ago. When running, everything looks aligned with no wobbling as far as I can tell. Wondering if anyone has had this problem. Don't know if the tensioner is able to be adjusted. Any help would be greatly appreciated.
Thanks!

Hi,Just replaced all above today 4th time it has to be a factory problem, that no ones talking about

 

[johnboy1313]

Get the bracket from a third gen and a 14mm crow's foot for your torque wrench. The third gen bracket is solid stamped steel, not the cast pot metal bracket that came on the second gen. It also doesn't have the square holes in it either. The crow's foot allows you to get the proper torque without removing the tensioner. The solid bracket is a lot stronger.

 

[eksine]

Hi,Just replaced all above today 4th time it has to be a factory problem, that no ones talking about

it's not a "factory problem" if you read through the thread you would see it's user error. please read the thread

 

[daherbie]

the TSB/note above came out in '04 and apply to '99-'04 ody's but i just had a 2008 bracket/bracket bolt break a couple months after the timing belt/waterpump, PS belt were replaced (along w/ both tensioners,etc). The same problem can still exist on a '08 ody if that lower bolt is not torqued right?