I have a 1995 Discovery adn the alternator no longer works. I tried to unbolt it, and ended up rounding the bolts so the wrench no longer works. I then used a hacksaw and tried to cut the bolts off, that didnt work to well either. anyone have any suggestions on how i can remove the alternator?

 

Forgive us Autocckr2. This one is sad enough to create a great reluctance to reply. However, let's forget about should-have-dones and speculate on cures.

For a perfect gurranteed solution, you now need a machinist and he will need space. He won't have the room to work unless you either remove the engine, or remove the head the alternotor is attached to and bring the lot to his shop.

However there are still other (small) chances that you can remove the alternator. 1. Soak the bolts with Liquid Wrench", an excellent penetrating oil, 2-3 times a day for 4-5 days. If you are ABSOLUTELY sure you have cut off all the bolts, I would consider trying to crowbar the thing off. However, I am leery that you have left a bolt on. I suggest you consider sacrificing the alternator (which sadly was easily repairable). This will give you a better view of what is happening.

The hope is that with all stuff off, the ends of the bolts you sawed that still remain outside the heads and removable. If that is not possible, the best soldution is precision drilling and then the use of an extractor. Precision drilling is likely precluded with the engine/head in the car. If he can extract the bolts, the machines will drill them out and use Time-serts (which I find much better than Helicoils).

The whole trick is not to continue the domino effect of damage. You would not believe how far it can go.

Good luck.

James