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Denso Alternator 01 Caravan HELP #978436
04/22/11 11:31 PM
04/22/11 11:31 PM
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Background:

Trying to track down bad bearing sound in the Step-Ds 3.3 with 113k. Can hear the noise under electrical load (lights and radio or a/c) at idle, intermittently. Goes away with any individual accessory off. Noisiest when compressor is running. A/C works great. Idling alone there's generally no sound.

Changed the h2o pump cause I felt some play. Not the problem. Mopar unit $105 w/ gasket .

Ran with the serp belt off. Noise gone. Could not locate using hose/tube method. Could not locate hitting bearings w/ oil. No sign of metal specks.

Alt works fine. I noted it has play. Not in/out play, but maybe 1/8" slop when pulley is rolled in opposite direction. bearings feel fine/ smooth/ nose free.

Is this play normal?

Other sugg, tests or known prob spots?

Help appreciated.


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Re: Denso Alternator 01 Caravan HELP [Re: A38s!] #978437
04/22/11 11:39 PM
04/22/11 11:39 PM
Joined: Jan 2003
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Eagle, Idaho
Neil Offline
The Doctor is in.
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The Doctor is in.

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Are you sure it's not the AC unit doing the talking?

Re: Denso Alternator 01 Caravan HELP [Re: A38s!] #978438
04/22/11 11:56 PM
04/22/11 11:56 PM
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chicagoland,usa
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buildanother Offline
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I have heard of some sort of spooky pulley on some of those vans alternators. Some kind of engage-disengage feature or something.

Re: Denso Alternator 01 Caravan HELP [Re: Neil] #978439
04/22/11 11:57 PM
04/22/11 11:57 PM
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No. Not certain. 'Feels' fine. Then so do the PS, Idler, Tensioner. I don't want to swing and miss again.


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Re: Denso Alternator 01 Caravan HELP [Re: buildanother] #978440
04/23/11 12:01 AM
04/23/11 12:01 AM
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When I twist the alt forward-back (like safe combo). It's got that slack in it.


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Re: Denso Alternator 01 Caravan HELP [Re: A38s!] #978441
04/23/11 12:09 AM
04/23/11 12:09 AM
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Eagle, Idaho
Neil Offline
The Doctor is in.
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No way to run the engine with the AC pully omitted? Can you have someone switch the AC on while you put your ear close to it?

I have killed a few alternators, but they have always spun freely when I took them off. Seems like if the bearing was going out you would be able to feel it. I guess you could always go to the wrecking yard and get a used alt. for cheap and try it. If it works keep using it or trade it in for a core and keep your noisy one for a spare.

Re: Denso Alternator 01 Caravan HELP [Re: Neil] #978442
04/23/11 12:23 AM
04/23/11 12:23 AM
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I was able to listen up close while the compressor cycled, couldn't pinpoint.

Here's that crazy alt pulley, BTW.

6598312-100_0128.jpg (43 downloads)

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Re: Denso Alternator 01 Caravan HELP [Re: Neil] #978443
04/23/11 12:31 AM
04/23/11 12:31 AM
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Quote:

No way to run the engine with the AC pully omitted?




No straight line from the crank to the alt w/ a/c between. I suppose I hasta throw used jy parts at it.


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Re: Denso Alternator 01 Caravan HELP [Re: A38s!] #978444
04/23/11 01:53 AM
04/23/11 01:53 AM
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A tad North of Indy
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Blown71X Offline
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You have 2 choices, either replace the alternator or get a new pulley, That pulley has a overrunning clutch in it and is a very common problem.
Take the alternator off and pop the plastic cover off the end of the pulley and you WILL find it all rusty.
They will make noise in 2 places depending on how bad the clutch is rusted.
One is the pulley itself, the other (also caused by the pulley) is the belt will flutter in the span between the crank and the A/C compressor.
Touch the throttle or take away any loading and it will quit.
There is a special tool to remove it that dosen`t work worth a crap....Take a 17mm headed bolt, flat washer and nut... screw them together, weld the nut to the bolt, pop the plastic cover off, insert the bolt head into the pulley, give it a few good quick pops with a impact and it will screw right off

Current dealer part number for the pulley is 4861506AH $98.85

Rick

Edit: if you want to check it, looking at it from the front of the pulley it should drive the alternator stator turning in a clockwise motion.
A good one will smoothly (keyword) freewheel with some slight tension in counter clockwise rotation. if it won`t freewheel it IS bad.

Last edited by Blown71X; 04/23/11 02:20 AM.

Blown71X V2.0 under construction 71 Cuda 383 4-SPD (maybe for sale) 2010 Challenger B5 Classic
Re: Denso Alternator 01 Caravan HELP [Re: Blown71X] #978445
04/23/11 02:40 AM
04/23/11 02:40 AM
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Madison Wi
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Quote:

You have 2 choices, either replace the alternator or get a new pulley, That pulley has a overrunning clutch in it and is a very common problem.
Take the alternator off and pop the plastic cover off the end of the pulley and you WILL find it all rusty.
They will make noise in 2 places depending on how bad the clutch is rusted.
One is the pulley itself, the other (also caused by the pulley) is the belt will flutter in the span between the crank and the A/C compressor.
Touch the throttle or take away any loading and it will quit.
There is a special tool to remove it that dosen`t work worth a crap....Take a 17mm headed bolt, flat washer and nut... screw them together, weld the nut to the bolt, pop the plastic cover off, insert the bolt head into the pulley, give it a few good quick pops with a impact and it will screw right off

Current dealer part number for the pulley is 4861506AH $98.85

Rick

Edit: if you want to check it, looking at it from the front of the pulley it should drive the alternator stator turning in a clockwise motion.
A good one will smoothly (keyword) freewheel with some slight tension in counter clockwise rotation. if it won`t freewheel it IS bad.





Its the clutch. I had the same issue on mine. It will fail completely eventually.


I used to care but....... things have changed
Re: Denso Alternator 01 Caravan HELP [Re: A38s!] #978446
04/23/11 08:36 AM
04/23/11 08:36 AM
Joined: Jan 2003
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Niles , Ohio
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therocks Offline
oh wait.but hey.lets see.oh yeah.
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I agree its probally the alt clutch.Ive changed quite a few because of them going bad.Rocky


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Re: Denso Alternator 01 Caravan HELP [Re: therocks] #978447
04/23/11 05:08 PM
04/23/11 05:08 PM
Joined: Jan 2003
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KS
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I've been through this and my dad recently went tthrough this and I'm 100% confident it is the ALTERNATOR. When the same noise started on my 02 Grand Caravan I had it looked at and was told it was the a/c compressor. Fortunately I still had a bit of my extended warranty left so the shop fixed it and it cost the warranty company $1200+. A little over a year later same issue and I went back to the same shop. The owner said it was the bearings in the alternator and they had several in with the same problem. I replaced the alternator and no issues. My dad had the same issue on his 05 T&C and a shop replaced the belt tensioner. He told me about it and I told him they were wrong and it's the alternator. He took it back and they put the old tensioner back on and replaced the alternator and it fixed it. The shop owner had never heard of it but he was glad to have the info. Just my ...

Re: Denso Alternator 01 Caravan HELP [Re: 68SportSatvert] #978448
04/29/11 12:09 PM
04/29/11 12:09 PM
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Dontcha hate when you never hear back?

Wanted to follow up and say THANKS .

It indeed was the Alt Decoupler. I priced the removal tool @ $85. Didn't want to wait and will prob never need it again, so I fabbed one as suggested. Easy peasy.

Again, Thanks!


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