Editing GM CS 144 alternator repair and replacement

{{copyright}} ==Preamble== GM vehicles in production from late 1995 to 2007 use the CS 144 alternator in all heavy duty applications that require a 135/140 amp charging system. You will find two videos that walk you through the diagnostics and repair of the CS 144 alternator even if you are a first-timer. Sit back an absorb the information that this technician offers you. Feel free to stop and jot down notes along the way. ==Exploded view CS 144== [[Image:DR-CS144_Late__exp_view.jpg]] ==Diagnostic and Repair Video== *CS144 Alternator Rebuilding, [http://www.youtube.com/watch?v=riYZssdSmXY Part 1]. *CS144 Alternator Rebuilding, [http://www.youtube.com/watch?v=vKbX7mezuFM&feature=related Part 2]. Or, go to this link directly: [http://alternatorparts.com/CS144_alternator_repair_video.htm Alternator repair video]]. ==Replacement parts== Stator P/N 04963 $50.00 [[Image:04900_stator.JPG‎|frameless|300px]] Rotor P/N 04963 $65.00 [[Image:04963_rotor.JPG‎|frameless|300px]] Bridge Rectifier P/N DR5179 $33.00 [[Image:Dr5179_brid_rect.jpg‎]] Heavy Duty Bridge Rectifier DR 5180PF $45.00 [[Image:Dr5180pf_HD_brid_rect.jpg‎]] Regulator P/N 10356 $50.00 [[Image:10356_regul.jpg‎]] Capacitor P/N 6316 $ 10.00 [[Image:6316_cap.jpg‎]] Brush Holder P/N 39-108-3 $10.00 [[Image:39-108-3_brsh_hldr.jpg‎]] Bearing (needle type) P/N 09780 $10.00 [[Image:09780_need_brg.JPG‎ ]] ==Most common causes of alternator electrical failure== ===Short term (quick) damage:=== * One relatively common cause of alternators is "ground lift" where a poor connection causes high levels of electrical "noise" in the system. This noise in the form of voltage pulses can exceed the breakdown voltage of the diodes and compromise reliability. A good ground from alternator to engine block to chassis/battery is paramount to a reliable electrical system. * Another major cause is "load loss" where a poor connection loads and unloads the alternator on the plus side of the system. This is akin to disconnecting the battery while the engine is running. The loss of load on the alternator can damage the diodes due to over voltage. ===Long term damage:=== The component that has the highest failure rate on most alternators is the '''bridge rectifier'''. The bridge rectifier (aka rectifier) is the component that converts the ''alternating current'' (AC) that an alternator makes to ''direct current'' (DC) for use by the vehicle. Over time or under high demand situations the diodes in the bridge rectifier can become weak, they don't do as good a job as they did when they were new. You can tell your bridge rectifier is going bad when you first start a cold vehicle and it charges better at first compared to after it warms up. As the diodes in the bridge rectifier heat up they don't work as well. In high demand situations the more AC power the alternator makes (based on demand) the more power the rectifier has to convert to DC, leading to a greater chance of diode failure. ===Battery terminals=== [[File:Bad batt clamp term.jpg|thumb|220px|left|Clamp-on replacement battery terminals are to be avoided!]]Do not be tempted to save money by using one (or more) of the cheap, clamp-on style battery cable terminals. Even if they are tight and look fine, all too often they will cause high resistance and can make it seem like the battery is bad, etc. If the terminal fails on a cable there are better terminals that may be used to replace them, or the entire cable can be replaced with a cable having a larger diameter and quality terminals already installed. <br style="clear:both"/> [[Category:Engine]] [[Category:Electrical]] [[Category:GM]]

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