Has anyone run into an issue with alternator to valve cover clearance? 1989 5.0 tpi, the boss sticking out of the rear solid hits my tall aluminum valve cover , can't install it. mine has the lug sticking out that accepts a bolt thru wire. can't even reclock it because i can't get it apart to get case attaching bolt riser past lower mounting bolt boss. hopin someone has seen this and has a cure. i believe i need a solid half in less sticking out. Thanks!

 

Mark the spot and massage the valve cover enough to give adequate space for the lug.

Hit up a shop that does aluminum and have them notch the area and re-weld it

 

or take the bolts out of the back of the alternator and turn the case, AKA clock it, so it fits correctly without all that nonsense you wrote..

 

Or put valve covers on it THAT FIT.

The problem isn't the alt, it's the VCs.

 

Might gain enough clearance if you take the alternator apart and swap that lug type output terminal to the stud and nut style, trim down the stud and use a thin nut.