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Alternator Replacement Guide

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  • #31
    Hi JimmyC,

    I have a late 2009 Prado 150 and the battery light was on. i charged the battery started the prado and found that the battery light was still on, and the battery showed no charge, 12.4v (same voltage as before starting)
    i replaced the alternator with an alternator from REPCO (OEX DXA552U).
    i started the Prado, but the battery light was still on, an slightly flickering. however the voltage was up around 14V.
    when the i rev the engine, the battery light goes solid, but goes back to almost flickering off when the engine goes back to idle.

    Have you or anyone else had a similar problem?
    btw as far as i can see, there is no alternator booster diode fitted.

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    • #32
      Hi
      how come I can’t see any photoes on the link to the photo webpage. Could you please tell me how, especially how to unplug the electrical plugs on the alternator. Thanks
      TD

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      • #33
        I can't see the photos either. Just press the plastic lock tab in with your fingers and the plug will pull out (or use a flat screwdriver gently, no force). I installed a cheap 130A alternator $155 on ebay. In step 8 you need to push the bush in using a vice to a width of 58 mm like the old unit, the new one was at 65 mm so obviously won't go in until adjusted. Step 11 me too, the lower bolt won't go in unless you loosen the other bolt on the bracket to let it move a tiny bit. The cheap alternator DID NOT have an overrunning alternator pulley just a rigid one. That's one reason for the low cost. The overrunning pulley costs $90-150 so almost as much as the Chinese alternator.
        2008 D4D GXL

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        • #34
          Mine has just gone in 2009 150 series, only 130000 km. Not a great life considering the toyota tax in my opinion.

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          • #35
            Hey guys, Thanks heaps for the guide. Is it similar job on the 90 series? I bought a new alternator as I'm going to rebuild the old one and keep it as a spare. I have a diesel with two belts on the pulley

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            • #36
              Put another alternator in my 2010 GXL last week, I say another as that's the third alternator in the vehicle! The first one went after 100,000km, some sort of internal fault, and was replaced under warranty. That one has now done 90,000km and has been getting gradually noisier over the last few weeks, I thought it was this bearing at the front end...



              So I bought that bearing, pulled the alternator out and pulled it apart. Turns out it wasn't that bearing, it was this one at the other end of the shaft...





              And that one isn't meant to be replaced, it's not even listed as a part with Toyota! I'm sure I could purchase the bearing from any bearing place but I couldn't get it off with the tools I had and as it had 90,000km on it I elected to just replace the alternator with a new one. $693 from Toyota after I got trade price.

              To just remove and replace the alternator took me just over an hour. I've put some torques below in case anyone is interested.



              [B]2010 GXL Prado D4D Auto[/B] - ARB Deluxe winch bar, Roadsafe recovery points, Rhinorack Pioneer platform, AMTS fuel filter/compressor combo bracket with FM100 filter and ARB compressor, Maxtrax, TIN175 transmission oil cooler bracket and tranny cooler. I'm sure I'll find something else....

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              • #37
                Can't say thankyou enough for this post. My alternator failed a few weeks ago in Alice Springs while on a trip and thankfully Repco had stock. As I had done this at home a couple of years ago it was a pretty straight forward operation & the trip could continue as planned. One thing to note is that the dash battery light did not come on, it was only because I had previously installed a volt meter that I knew there was an issue. I have a Toyota mechanic contact & he advised that the light will not always come on when the alternator fails, so I would encourage fitment of a dash voltmeter so that charging is always monitored.

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