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how do I replace the altenator on a 2004 town and country?

20K views 18 replies 11 participants last post by  Jeepman 
#1 ·
Does anyone know where I can get step by step directions on replacing the alternator on a 2004 t&c? I have done it on other vehicles but never a mini van. The repair shop wants over $400 to do the work and that seems pretty crazy to me but im new to this van. Any advice would be greatly appreciated.

Thanks
 
#2 ·
REMOVAL
1. disconnect the neg term
2. Disconnect the push-in-field wire connector from the back of the generator
3. Remove the nut holding B+ wire terminal to the back of the generator
4. Remove the B+ wire from the generator
5. Raise and support the vehicle
6. Remove the right front lower splash shield
7. Remove the serp belt
8. Remove the lower oil dipstick bolt
9. Remove the wiring harness from the dip stick tube
10. Remove the the 3 mounting bolts
11. Lower the vehicle
12. Remove the oil dipstick tube from the vehicle
13. Roll and remove the generator

INSTALLATION
Reverse the procedure... Any problems PM me... Good Luck:thumb:

Taken from AllData 9.8
 
#4 ·
I think also that those instructions would assume that the van has an EGR valve in the way of removing the alternator - generally what you've got on those vans is two alternatives:
1) remove/move the EGR valve to get the alternator out.
2) remove/move the dipstick tube to get the alternator out.

I'm going to be doing a similar job on my 2005 (3.8 w/EGR) in the near future, so I'm weighing my options on what way to get the alternator out as well. The nice thing for me is that my alternator is still charging just fine, so I'm not pressed into doing the job immediately.

Nate
 
#6 ·
It's hard to get the EGR valve out without first removing the alternator. When I changed my EGR valve, I struggled so much to get the bottom bolt off that I finally decided to just take the alternator off. It was pretty easy to do.

Removing the dipstick tube is very easy.
 
#8 ·
Easier access to alternator and getting in/out without removal of EGR or dipstick

Got an easier fix on this fellas. Take the crossbar support out above the radiator fans (if I recall correctly, two bolts on each side). There is one harness to release on the fan on the alternator side and it literally slides right out. You have all the space in the world to remove the alternator as well as put it back it without any B.S. Once the alternator is back in, tightened down, serpentine belt back in, etc, slide the fan back into it's slot, tighten it down with the one bolt holding it in place, connect the electrical harness, replace the frame crossbar (this is the same cross bar that holds your hood release, so it's a good time to grease that bugger down while you are at it). Voila, easy peasy, no removing EGR valve, no removing dipstick, nothing. Taking that crossbar and fan out took maybe 5 minutes.
 
#10 ·
For the belt, many auto parts stores have "tool loaner" programs that you can get a belt tensioner tool for. I just bought one at Harbor Freight and called it done. <$30
For the electrical connectors, if they have the (red) locking slides on them, release the lock and push down on the tab on the female connector while pulling on the male connector. The other style has the clip on the female side that engages the tab on the male side, and you need to lift the clip away from the connector to release the connection
 
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#11 ·
It's less than an hour's work so I would skedaddle away from that repair shop. If your vehicle doesn't have an EGR valve, the job is basically unbolting and bolting plus releasing the serpentine belt. If you have an EGR valve, then the bottom of that needs to be unbolted, or the dipstick tube removed or the fan shroud removed in order to wiggle the alternator out after you unbolt it.

For my 2002 the small electrical connector just slides off and back on, no locking tabs plus the big electrical connector just unbolts. Remember the washers when bolting that electrical back up.
 
#12 ·
Does anyone know where I can get step by step directions on replacing the alternator on a 2004 t&c? I have done it on other vehicles but never a mini van. The repair shop wants over $400 to do the work and that seems pretty crazy to me but im new to this van. Any advice would be greatly appreciated.

Thanks
It's less than an hour's work so I would skedaddle away from that repair shop. If your vehicle doesn't have an EGR valve, the job is basically unbolting and bolting plus releasing the serpentine belt. If you have an EGR valve, then the bottom of that needs to be unbolted, or the dipstick tube removed or the fan shroud removed in order to wiggle the alternator out after you unbolt it.

For my 2002 the small electrical connector just slides off and back on, no locking tabs plus the big electrical connector just unbolts. Remember the washers when bolting that electrical back up.


Five year old post. I would hope he figured it out by now.
 
#13 ·
#18 ·
We should start a new thread - "How to remove serpentine belt". In my 2002, I have done it with a Crescent wrench on the square stub that sticks fwd on the tensioner. It is easier w/ front tires on a ramp, but I did it at a rest stop once lying on the ground. I tied a rope thru the hole on the end of the wrench handle so my son could pull up to help, but even a little kid could help by keeping tension so the jaws stay on the tensioner. You must push up with ~20 lbf to release tension. Some cars have a 1/2" hole for a socket breaker-bar, but I didn't see such, just the male "stub".

In my rest-stop repair, I did it 3 times. The belt kept coming off because the plastic power steering pulley had cracked, so my fix didn't hold. I then used a nylon rope tied tight w/ a barrel nut. That got us 15 miles to the next city but must have been slipping on the alternator because the battery died. Next time, I would route the rope to just turn the water pump to drive as far as the battery charge allows, which isn't very far in newish vehicles w/ electronic fuel injection.
 
#19 ·
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