Date: Wed, 6 Jan 2010 02:06:32 -0600
Reply-To: John Rodgers <inua@CHARTER.NET>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: John Rodgers <inua@CHARTER.NET>
Subject: Alternator Repairs
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I've been plagued by alternator problems and having three vans - and
being the frugal (read "tightwad") type that I am, I was doing the
swappy-swappy thing with them to keep my daily driver roadworthy.
Finally, the last unit quit. I took it - a Beck-Arnely - and had it
tested at Advance Auto. It was dead. I thought "enough of this - buy a
replacement"! Well, the cheaper replacements for the Bosch alternators -
exchange - around here are priced about $125.00. Other places - even
with list vendors - it varies. I wanted a Beck-Arnley rebuilt because
they seemed to last a lot longer, but when I checked them out - exchange
they were $245. Ouch!!
Well, I was holding onto my buffalo/Indian head nickel so hard that you
could hear the Indian grunt and the buffalo squeal over those prices,
when it occurred to me - these alternators are simple, the shaft has two
brush rings, and two brushes, and this alternator has no shaft looseness
of any kind, so it should be in good mechanical shape. Besides
bearings, there is not much else that can go wrong but for the brushes
and the rectifiers. Close examination showed that there is a one-piece
rectifier/brush-holder that mounts to the back of the alternator, and I
figured, "how simple is that to replace". I ordered one up on E-bay for
12 bucks, and it was in hand in 3 days. When it arrived, I removed the
two screws on the back of the alternator holding the piece in place.
Inspection showed one brush was worn completely out, and was stuck in
the older, not making contact with the commutator ring o the shaft. I
looked a the rings on the shaft and saw they were oxidized. I whipped
out a little piece of 600 grit wet/dry sandpaper and dry - pressed it to
the commutator rings while turning the shaft. In a few turns the rings
were nice and shiny. A blast of compressed air cleared any dust and
debris. In inserted the new brush-holder/rectifier with the new brushes,
buttoned it up, and hauled it away to Advance Auto. This time, the bench
check showed maximum power output. The thing worked perfect. It is now
ready to re-install.
My point - if your alternator has seemingly failed - no output, or
minimal output - remove from the vehicle, rotate by hand and see if the
shaft and bearings are OK. If so, remove the rectifier/brush holder and
inspet the brushes, and also check the commutation rings. If oxidized,
polish with the 600 grit paper, and install a new brush holder with
brushes and rectifier. Your cost - a little time and a $12 part.
$12 bucks vs $125 or $245 is hard to beat.
--
John Rodgers
Clayartist and Moldmaker
88'GL VW Bus Driver
Chelsea, AL
Http://www.moldhaus.com
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