Editing Rebuild an alternator

{{youcanedit}} ==Rebuild Your Alternator== These days alternators are getting more and more costly (up to several hundred dollars depending on your issue...) while intermediate rebuild kits are very inexpensive and once you've done it, very simple to do. Assuming the alternator didn't burn up electrically (windings melted down) these simple steps will net you a very reliable operating alternator and save you about $100 bucks in the process. If you plan to rebuild your alternator, some easy steps to a DIY project are below. == Removal and Clean up == *Remove it from the car *Get about 2 or 3 cans of gunk, go to the coin wash, spray it with the gunk, then let it soak 5 minutes... THEN set the wash to degrease, spray that for 5 minutes. Follow this with a rinse for 5 to 10 minutes. Allow dry time OR better yet air blow dry.. == Disassembly == *Mark the case halves so you can get them index properly when you re-assemble it. It can go 3 or 4 different ways. *Halve the cases *Remove the brushes, brush holder/followers (depending on kit) *Remove the Bearing *Remove the bush (depending on kit) *Remove the regulator and install the new one. *Remove the rectifier Diodes and install the new ones. *With a fine Emery or Crocus Cloth, Burnish the brush pickups or (Slip rings) on the rotor assembly until smooth and shiny. == Installation and Inspection == * Install your new bearing, but before you do, get a SMALL sharp punch and carefully put a dimple in the race each 1/3 rd the way around. This will prevent the Bearing from EVER spinning in the race. It will be a tiny bit harder to put the cases back together, you might have to tap the halves with a rubber mallet. * Install the bushing. (depends on kit) * Where the brushes are, at the rear end bell, there should be a small hole that goes through to them. Insert a #40 drill bit or paper clip with the brushes fully compressed up. This will hold them off the slip rings while you insert the end bell. * Before reassembling the end bells to the body, inspect the windings. You are looking to make sure there is no worn insulating paint, or glyph. Also, where the windings terminate, check that there is no melted or splattered solder, and no cracked joints. If needed, Ohm the windings out, but... These usually last forever, and if they failed before, you'd know it... * Install the end bells to the body and properly 'clock' it for your application. Be sure the end bells are straight, and (if needed) tap the bearing half end-bell with a mallet. Secure with the bolts. * Lastly, spin it up by hand and ensure it spins free and quiet. Inspect the front fan blade, and reinstall on the car. [[Image:image03.jpg]] == Inspect the Hardware == If you notice white powder on the brackets or hardware, you have electrolysis going on there... (Mounts are aluminum and hardware/engine is steel... What were they thinking??) Remove and media or water blast them. Get some electrical bonding paste for aluminum wire and coat the bolts and mounts, anywhere they touch steel... That should give you a much better unit than you can buy over the counter... That will probably out live the car... [[Category:Electrical]] [[Category:Engine]]

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