Battery ligh dim and flickering at High RPM
 

Dear all,

I have a BMW X5 e53 2003 4.4i with a failed alternator.

I removed the alternator, took it into a shop for repair, once done I put it back in but while tightening one of the 6 bolts I managed to snap the one at the bottom. It's now stuck in there and it gets worse (alternator is still not working so I've got to get it out but now it's stuck to the alternator housing since I've the bottom bolt broken where no drill or any bolt extractor can get to.

Any idea how hard it is to remove the alternator housing? I want to remove it and have it outside the car in order to properly remove the bolt without damaging anything else.

Many thanks

Weld a bolt head onto the old broken bolt and wrench it out.

Not an easy job to take out - the alternator housing is part of the lower timing case cover on the M62

edit: If it's just the bottom bolt that you're working on, remove the plastic front under body cover and try getting it out from underneath.

Thanks for the suggestion but that is impossible because as I explained the bolt is at the bottom of the alternator and it's deep inside the whole, you can't weld anything to it.

Thanks I thought it might be difficult too, I've got some good news though I originally thought the alternator bolt whole is also threaded but it's not so it means I can pull the alternator out and the bolt would be left inside the housing.

Once I've got the alternator out, I'll have enough space to remove the bolt easily.

I'm going to try this tomorrow, I'll keep you all updated!

UPDATE:

I've now put the other alternator in and the light still comes on at High RPM.

I have tested this alternator and it gives about 13.4 to 13.5 volts and under high RPM it gives about 13.94 volts. Is this ok or is it too low?