0dyfamily· Premium Member
Virtually every alternator built for automotive applications grounds via the case. The bracket serves as a ground path, but ultimately its prime duty is to correctly position the alternator.Was working fine intermittently few days back. Now it is not working :-(.
There is no ground from the casing. I think this could be the issue. Where does the regulator get the ground from (casing?)? Does the casing get the ground from the alternator bracket? The alternator bracket is totally rusted. Should I replace it? Could this be the issue?
I don't have the torque values for a 2005 Odyssey, but you need to make sure these are torqued properly or the bracket can loosen, break bolts ... the results aren't good. Whether you replace the bracket or not, it needs to be correctly torqued on all fasteners.
The alternator has a burly roll pin in one side that fits into the "U-bracket." If you compress the side that sticks out towards the U-bracket with a big C-clamp and socket, it makes fitting the alternator easier.... I had to struggle a bit to press the alternator's bottom half into the slot ("U-bracket") with the holes aligned. Had to use a pry bar to align the holes. May be if you install the top bracket first it will easier to pivot the bottom part.
That contact with the "U-bracket" is your largest ground path. I typically clean those well, shine up with emery paper, coat with dielectric grease, and install. I shine up the big bolt's flange and coat the flange with dielectric grease, too.