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[kcl]

Changed a new regulator/brush pack to my alternator because the battery light came on all of a sudden. Seems to have cured it.

My problem: when fitting alternator back the upper fitting to block was not correctly seated, did not look careful enough and put in the bolt and started to tighten. As it felt loose I just tightened it more and then, crack. As said, the bolt did not go through the engine block fitting, I was only tightening the alternator "ears" towards each other resulting a crack in rear "ear". Not broken off, just a visible crack in the alloy alternator housing where the fitting "ear" rises from the body of it. Well, just had to have the car on the road so put everything back together with more care and it sits there ok, not moving or anything and it did torque up ok on both bolts, upper and lower.

My question: how much force/torque will the upper rear "ear" be carrying? Am I safe to drive it through holidays/next year/next decade or is it designed so that this crack will cause the whole alternator to drop at some point?

My assumption is that I'm ok with it and looking at the system it seems that it would carry on with only the lower bolt 

[waspy]

I would say that with the combination of vibration, hot & back to cold it's a matter of time before the ear fails.
I personally wouldn't trust it. How long it will last is a piece of string.
It looks like a new alternator, unless you can find an old one to swap over the parts.

[kcl]

Fair point there but still I want to imagine taht when three of the four holes are intact and the fourht one only partially damaget (now, when the bolt is on the crack is "tightened" also) it would have enough strength left... And, in comparison to some othe cars, the alternator is only hanging on three "ears, two lower for through-bolt and third one for tightening on the top...

[waspy]

If you're happy & prepared to take the risk
If it's meant to be fitted with four lugs then four lugs it is, but that's me

[kcl]

If you're happy & prepared to take the risk
If it's meant to be fitted with four lugs then four lugs it is, but that's me

I know that you are right and I do agree with you, the fourth lug is not there for fun and I should change it. BUT  I just wonder for mechanical/strength point of view and would want to hear also other opinions 

[waspy]

Say if/when the lug fails, this will put extra stress on the other lug/lugs & say that for what ever reasons one of these lugs has an hairline crack that you can't see & after time that one also fails.
Manufacturers spend time & money designing for a reason.

[kcl]

Say if/when the lug fails, this will put extra stress on the other lug/lugs & say that for what ever reasons one of these lugs has an hairline crack that you can't see & after time that one also fails.
Manufacturers spend time & money designing for a reason.

I know, they do. 

[Andy H]

Like you I have just fitted a new regulator to my alternator because the old one failed.

Two thoughts occur to me:
 - The heavy load occurs on the front two lugs
 - when cars had vee belts they only used 3 lugs.

My view is that you will probably not suffer any ill effects if you use your broken alternator but I would replace it anyway for peace of mind.