Any gotchas with 02 Astro AWD alternator replacement?

Filled up my Astro today. It wouldn't start back up. A jump worked, it wouldn't stay running long. I let the other vehiicle charge me up a bit so I could get it home. Battery light is ON. Charging gauge is low. And it dropped lower as I drove home. I believe the charging system is failing to charge the battery.

I think the alternator must not be working. Friends say Autozone will check charging system for free. I have my Harley trickle charger on it now. (Only charger I have)

Alternator looks tough to get at thru the hood. Is it easier thru the cabin?

Any advice to help make this task go more smoothly is greatly appreciated.

Donny B.

Hi Donny,
The red warning light coming on means the voltage regulator, (inside the alternator), is getting power and more than likely the alternator is faulty.

Alternator replacement is a breeze. Dog house does NOT have to be removed on 2002. Remove the following: Negative battery cable from battery, (5/16 bolt). Upper and lower air filter housings, air inlet hose from MAF sensor to adapter, (looks like an accordian) 5/16 hose clamps. Upper fan shroud, (3 10mm bolts go into radiator support, and 4 10mm bolts hold the upper to the lower shroud), pull the shroud out. 6" x 3/8" extension on a ratchet to relieve the tension from belt tensioner, slide belt off alternator. 2 13mm bolts hold the alternator on, remove them. Self adjusting spacers hold the alternator tightly in position even after bolts are removed, pry the alternator loose and pull it forward far enough to remove one snap in connector. Then a 10mm nut on the rear of the alternator holds the 10ga wire on. There is a spot on the fan where the blades are spaced wider apart than others, rotate the fan until the wider opening is lined up with the alternator and wiggle it out. 1/2 hour tops to remove it. Before installing the new alternator, push the self adjusting spacers toward the front of the vehicle, they'll only move about 1/8". When the new alternator is in position and the bolts are tightened, they will move the spacers where they need to be. Make sure the serpentine belt is aligned in ALL of the pullies. Put her back together and you're done! Be sure the battery is charged before you start the engine. Nothin' to it!

Much thanks old_master!

I followed your instructions and removed the alternator easily and quickly.

Do you have an idea of the cost for a new alternator from the chevrolet dealership parts department?

Can you offer any suggestions about purchasing a replacement. New vs remanufactured? Genuine Chevrolet parts vs aftermarket (autozone, advanced, etc.)


Again Thank you
Donny B.

I have installed Advance Auto Parts alternators on two of my three Astros. Remanufactured runs about $130USD and new runs about $170USD. I have installed one of each and when the third one goes, I'll install a remanufactured one on that one. Glad I could help.

I want to say thanks to you again old_master.

I have successfully completed the replacement of my alternator with a life time warranty remanufactured unit from advance auto parts. Your instructions were very helpfull. I am extremely pleased to have stumbled upon AutomotiveForums.com. You and blue_bowtie deserve many kudos for the help you us DIYers.

Donny B.