Can't get lower bolt on alternator back on, doesn't fit.
 

Is there a trick to get the lower bolt on the alternator. It simply won't slip over the housing, no matter how neatly line it up. Tried giving it some heat, banged on it with a hammer a little still won't slip over. Now i noticed the threaded bolt holder on the back bracket sticks out a little is this normal? It appears to be part of the metal assembly. Having a dickens of a time.

http://mendesonline.com/alternator.jpg

Have you mounted the alt and stuck a screw driver through the bolt hole? That should help line it all up.

Joshdub, no that wasn't the issue the holes for both the alternator housing, and the engine housing were both fine. I'm telling you I don't know how this was in there.

I took my 4" whell grinder and grinded down the back piece a little, bingo went in smooth like butter. I'm not sure how you guys get this in.

Us guys knows that you need to get a c-clamp with a large socket to push that piece back out a little so you don't need to take a grinder to it. Goes in smooth like butter all the time.

+1. I usually just thread the bolt into the sleeved nut and give it a couple of thumps with the deadblow hammer. An 1/8inch is all you need to move it back.

Dam, you know that's what I thought, as it's impossible to fit as is. I looked at it carefully but it looked like it was part of the housing. I didn't try a c clamp but I did thread the bolt and gave it a couple taps to see if that was would go in as again it looked like it was part of the housing. When I taped it didn't budget (I didn't take it too hard as I was afraid to damage the threads), so again I thought it was just part of the housing. Oh well.. I got it to work anyway.

I have removed the alternator twice on my '05 4.4 (N62 engine). One trick I discovered that would turn a 2 hours install job to 20 minutes job is to knock in the bolt hole metal gasket flush with the alternator before install as shown in the picture. Even new alternators have the gasket sticking out. The alternator slips right in with no struggles when the gasket is flush. That gasket bites into the block when you tighten the alternator mounting bolt and is what makes alternator removal or install such a struggle.

Here a video on how to push that sleeved back out so that the alternator goes in easily. It's at 5:30 into the video. Like I said before I use a c-clamp and a socket to push that sleeve out.

https://www.youtube.com/watch?v=7Z959grnL7s

Thank you - bottom bolt alternator N62 X5 E53 4.4i
 

Just to say you guys just saved me from hours of swearing and high blood pressure! And yes - this is a 2 year old thread but if I can save someone else from alternator misery then I feel that whatever happens my life has been worthwhile!