Got the battery not charging signal, determined alternator has failed. Now in process of removing and want to remove wiring bundle going to back of alternator with plastic plug, but can't pull plug out of alternator. Do I just pull it out? Can't see any plastic restraints I need to collapse or compress as I pull! So what is the trick to get that plug and wires out of the back of the alternator without destroying anything. Help!⁷

 

Wes, I'm kind of surprised that you haven't received an answer to your question from this forum. The collective wisdom about XKs here is phenomenal.

I am certainly not the one to help you with this, given that (1) my XK is still pretty new to me and (2) I have never removed and alternator from this (or any) car. But FWIW I did look at images of the alternator online and it seems that the connector should pull out straight with no damage. Again, I am hardly a reliable source for this advice, but that's what it looks like to me.

Have you already separated the cable from the alternator? If so, let us know how it went.

 

I can't see why it WOULDN'T be detachable. Inspect it for anything like a tab or slot that would be moveable or compressible.

 

He indicated he couldn't find any tabs to compress.

 

That's what I get for skimming and not reading the post.

Oh, hell, just yank on it but stop when you feel crunches or stuff breaking.

 

I'm pretty sure there are tabs holding it, just need to find how! Have you checked the workshop manual?

 

nothing in the workshop manual that describes it. It just reads, remove the electrical connections and the pic tells me it's tabbed but not clear enough to discern what type. Someone with a TOPIX subscription might be able to capture a better pic as TOPIX has some more detail than the service manual.

 

Do you have a a endoscope camera, that can maybe show you the tab? They are not that expensive. :-)

 

okay, so the alternator has failed. have you purchased the replacement alternator already? what does it look like?

 

just wanted anyone following this to know that I was successful in removing the alt plug. My issue was that I felt it would be better to remove plug before removing alt and trying to get plug out while being held only by wiring harness. Ended up fabricating tool made from 3/32" thick X 1" wide strap steel. Made slot in end of strap exact width of plastic plug and added a 1" wide piece of 7/16" bar stock tack welded to under side of strap to function as fulcrum or pivot point. Slot width was slight press fit on plastic plug and positioned directly under cast in prongs on the plug. It required some force to lever the plug straight up and out of the female portion of the plug residing in the back of the alt, but it popped out. Turns out there is a compressible retention strap on the male part of the plug that snaps over a index tab down in the side of the female part of the plug and that part got broken off during removal. That was not a problem because the broken part stayed with the alt which I was replacing. In my opinion the tool was the easy answer because due to very tight tolerances of the two plug halves, it was impossible to depress the retaining clip and pull with great force at the same time while only being able to use one hand reaching up to the alt from below. My tool worked for me and the project is complete and all is running well. I have no idea if Snap-on or any other tool mfg makes a plug removal tool.

 

Pics of the tool would be great! :-)

 

i'd still like to see the plug itself as well, this is interesting. very resourceful work!

 

I found this, but can't really tell much. Looks maybe like a friction-fit.

 

Cee Jay pic is very helpful ....maybe a small jewelers screw driver inserted at the locking tit location, Might be enough to not damage anything.
lube connector with dielectric grease upon reassembly ... next guy won't have to work so hard... just a thought.