Date:         Fri, 24 Nov 2000 10:53:13 -0500
Reply-To:     Richard Golen <rgolen@UMASSD.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Richard Golen <rgolen@UMASSD.EDU>
Subject:      Alt. light on dimly? Clean your ground connections
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Last night as we were heading through the woods and over the river
returning home from the family turkey-day, the alt. light came on in our 87
very dimly. With 55 miles to go, I shut off everything but the lights and
drove home expecting at any moment that the alt. would die.

Fortunately it didn't and we made it home. This morning (in a balmy 25
degrees) I decided to check the alternator out. The alt. belt was ok....in
August I replaced the regulator/brush unit, so I threw in the old one.
Still had the same problem.

Called the local FLAPS, they wanted $175 for a Bosch rebuilt unit (that
would raid my awning budget for next summer). I took the alt. out and took
it to the local alt/starter repair guy. Told him what happened, he put the
alt. on the test stand and it was charging perfectly.

He then popped off the regulator/brush unit and began attacking the
interior of the alternator with a piece of emery cloth. He cleaned all of
the ground contacts for the regulator on the inside (two little metal
springs) and on the surface of the alternator. When the alternator was put
on the test stand it was charging slightly better than before.

I asked him how much for his services, he said no charge..but I was
reminded to clean all of the ground contacts of the alternator next time I
do any "surgery" on it. So I went home, put the alternator back on, fired
the Westy up and voila! The light was off.

Lesson learned....and hopefully passed on to the rest of the list....when
replacing the regulator/brush unit on your alternators clean up all of the
ground (as well as the positive) connections!


Ric