All right. I realize I may sound mechanically idiotic here but here goes: Wife’s 2004 Accord has the electrical system warning light come on and after charging the battery sufficiently to test the electrical system Autozone tells me the alternator regulator is bad. So, I buy a new alternator, borrow the belt tensioner tool, and change the alternator. Near the end of the process I’m trying to screw the 5 mm hex terminal nut back on to connect the electrical wire, with the protective rubber boot getting in the way and in a cramped area. After probably 10-15 minutes of struggling with it, as feared, I drop the %^%$# nut and it doesn’t fall to the ground and doesn’t seem to be in the splash guard. Couldn’t find it. My wife needed her car and the wire connection seem to be on the post pretty good without the nut and the rubber boot seemed to help keep it there, so I did that and the car started and the electrical system warning light went off. The next day the warning light started flashing on and off. Meantime, I found 5 mm hex nuts at Lowes (10 for .80 versus around $7 for 1 online for the exact part through Honda). So, yesterday I went at it again trying to connect the wire. There’s a bigger/thicker hex nut closer to the alternator body that had sort of unscrewed itself and was covering most of the post. I tightened it and with the wire not on the post yet tried one of the Lowes hex nuts. It started to take on the threads but then would not easily go further (I didn’t try to force it). Also, I’m not sure but the post with the threads although not blackened seemed like it may be a little fried (sort of like an old spark plug). Can anyone help with the following questions:

1. Should the car be started/driven before the wire is properly connected to the alternator?

2. Is there a proper way other than a hex nut to secure the wire to the terminal?

3. Is there a proper way to clean the post/threads (so perhaps the Lowes hex nut will screw on easily)?

4. Should the Lowe's 5 mm hex nut fit and, if so, should I use more force to screw it on the post?

5. Should I just go ahead and order the $7 Honda hex nut?

6. I’m thinking I’m going to have to take the alternator off again and then before remounting it hook up the wire in uncramped conditions, but I’d rather not. Does anyone know a trick/have a technique for connecting the wire while the alternator is mounted (for me the rubber boot, little amount of exposed thread when the wire’s on the post, and cramped working space make if very difficult).

Thanks!

 

1. Should the car be started/driven before the wire is properly connected to the alternator?
Answer: No, you will get intermittent performance.

2. Is there a proper way other than a hex nut to secure the wire to the terminal?
Answer: Not securely enough to be sure it would work. Go to Honda and buy the nut.

3. Is there a proper way to clean the post/threads (so perhaps the Lowes hex nut will screw on easily)?
Answer: Wrong thread pitch on Lowes nut is likely. Don't force on!

4. Should the Lowe's 5 mm hex nut fit and, if so, should I use more force to screw it on the post?
Answer see 3)

5. Should I just go ahead and order the $7 Honda hex nut?
Answer: Yes, or go to alternator repair shop who should have correct nut.

6. I’m thinking I’m going to have to take the alternator off again and then before remounting it hook up the wire in uncramped conditions, but I’d rather not. Does anyone know a trick/have a technique for connecting the wire while the alternator is mounted (for me the rubber boot, little amount of exposed thread when the wire’s on the post, and cramped working space make if very difficult).
Answer: Any installation of nut requires battery negative post to be removed to avoid potential short (wire is always live!) w/ battery damage and/or fire. I've had success in some cases w/ jamming the nut in a deep or shallow socket (depends on access space) w/ paper towel to hold the nut in socket. The socket enables the nut to be started easily.

good luck

 

That was a darn good reply Texas Honda. Thanks! As it happens, I live just up the road from you in Cypress. Is there an alternator repair shop up here you'd recommend to get the nut?

 

Or.... you might be able to find a better hardware store that has metric nuts in different thread-pitches.

 

I don't know any shops to recommend. Suggest google or Angie's List, if you have an account. I think a Honda Parts shop would be best bet. Most repair shops are not going to be interested in a single nut to help you.

good luck

 

Thanks guys!