Unexpected snag while removing alternator

[evbrad2002]

I am in the process of changing timing components and decided to go ahead and replace the oil filter gasket while at it.  I've hit a snag while trying to remove the alternator and was hoping someone had some experience with this.  First, yes, I have removed all of the bolts necessary to remove the alternator.  It should simply pull up off the bracket at this point.  However, the alternator is hung up at the rear pivot point.  It is difficult to see in the small area but it appears that there is a shaft (hollow so that bolt passes through) attached to the alternator continuous with the rear bolt hole and it seems to insert into the bushing.  At first I thought it was the bushing inverted in some way but it is metal and attached to the alternator from what I can tell.  I can't slide the alternator back far enough for this shaft to clear and allow me to free the alternator. 

I've taken alternators out of other cars and have never seen anything like it.  It's almost like an incorrect alternator was installed at some point, but if it went in, it's gotta come out, right?  Before I take out the various persuadinators and go nuclear on it, I wanted to see if this rings a bell for anyone and if a more, umm, elegant solution might be offered.

[bmwman91]

There are metal sleeves in the rubber bushings. The alternator likes to get stuck on them. I usually have to get out a pry bar to pop it free of them.

[evbrad2002]

The persuadinator it is then.   Looks like new bushings will be in order.  Thanks for the tip.

[bmwman91]

You may not even need new bushings. The alternator housing is fairly malleable and torquing down the long bolt that runs through the bushings seems to bend the housing tabs so that they grip the bushing pins. Just think about how much fun the stupid thing is to put back!

[evbrad2002]

Attached is a pic showing the metal spacer/bushing pressed into the back pivot bolt hole.  This was recessed a bit into the bushing preventing it from coming out.  Is this typical for M42 alternators? I don't recall other alternators I've removed having this pressed in piece. 

(BTW, I realize this is associated with my other post regarding my timing case rebuild, so if admin needs to combine or what have you, I understand.  Just thought others might run into a similar issue when removing alternator so thought I would give it its own thread.)

[bmwman91]

Is that the metal spacer thing from inside the rubber bushing? If so, that is not normal and it explains some of your difficulties.

[evbrad2002]

Is that the metal spacer thing from inside the rubber bushing? If so, that is not normal and it explains some of your difficulties.

The metal liner in the rubber bushing was intact.  What you see in the pic is a piece pressed into the alternator assembly.  It was caught in a slight impression on the bushing, deepened I'm sure when the pivot bolt was torqued up.  It was happy where it was and didn't want to come out and play.  Perhaps my memory fails me but I just don't recall seeing this on other alternators I've removed.  Perhaps an aftermarket piece using inserts of various lengths for different vehicles?

[bmwman91]

Hmm, yeah it is possible that someone replaced the alternator with some sort of universal one and had to stick the spacer in to make it work.