Greg, You can change out the regulator without removing the alternator. If you remove the regulator you will no doubt find worn or disconnected brushes. In cold weather especially the copper braid that connects the brushes th the regulator circuit will fatigue and break. You can probably take the VR to your alternator guy and get your brushes replaced. This is usually what fails on an alternator. If your bearings are not all loose, no need for a complete R&R, John

On Jan 7, 2008 1:21 PM, Greg Potts <greg@pottsfamily.ca> wrote: > Hi John, > > OK, I've put a charged battery into it and the light is still on. The > voltage at the battery is reading just barely above 12V which tells > me the alternator is not doing its job. The light does not go out > when the engine is revved up (which it did before the stall out on > Jan 4th) but it does flicker a bit in brightness. > > The ground strap was loose on the original battery, but was not > disconnected while the engine was running; The engine had already > died out when I discovered it was not fully tightened down. I will be > replacing it ASAP with a heavier and slightly longer cable. > > I don't have a spare VR on hand, and my local NAPA wants $49 for a > BERU voltage regulator vs $89 for the Bosch regulator. Are these > prices in line? I haven't yet looked close enough to determine which > alternator i have. > > My local auto-electric rebuilder did the bosch alternator on my > aircooled bus for $125 last summer so I'm thinking that would be a > better choice. It doesn't look like the re-and-re will be all that > much trouble and having the alternator completely redone seems like a > better idea... > > Additional guidance appreciated... > > Happy Trails, > > Greg Potts > 1973/74/77/79 Westfakia "Bob The Tomato > www.pottsfamily.ca > www.busesofthecorn.com > > > > > On 5-Jan-08, at 12:03 AM, John Meeks wrote: > > > Greg, > > My money's on worn alternator brushes. Got a spare voltage regulator? > > Let us know what you find. > > John > > > > On Jan 4, 2008 8:33 PM, Greg Potts <greg@pottsfamily.ca> wrote: > >> Hi Volks, > >> > >> I was driving the vanagon on the highway tonight and as I cruised up > >> the off-ramp I saw the battery warning light was on. I figured it had > >> spit the belt, and made a note to deal with it as soon as I got home, > >> since I was only a few miles further. And then as I pulled away from > >> the off-ramp, the light went out. Uh-oh, says I... That's the sign of > >> a wonky alternator, or a VERY loose belt. So I kept watch on the > >> tachometer to get an idea of how bad the problem was... it seemed to > >> vary a bit, lighting up when below 2,200 to 3,000 RPM. > >> > >> But it didn't last 7 minutes before the engine quit completely. I > >> still had dash lights and emergency flashers (dim, and fast- > >> flashing), but the starter wouldn't even click. I checked the belts > >> and they were OK, but the battery connection was pretty loose. I > >> pried off the + terminal without much trouble at all. Luckily I was > >> very close to my brother's house at the time and he and I were able > >> to tow the vanagon back to my house. > >> > >> So what's the prognosis? Did the loose battery terminal allow the > >> battery to run flat, or does this pattern indicate a failed > >> alternator? I can throw a spare marine battery into it tomorrow to > >> get it running again; once it's lit up I can put a voltmeter on it > >> and see if it's charging. > >> >

-- John Meeks

'91 Multivan, '85 GL bits Northern Michigan KC8ZFN

Vanagon Rescue Squad http://www.vanagonauts.com/Vanagon_Rescue_Squad74.htm