Rebuild an alternator
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| − | == | + | ==Introduction== |
These days alternators are getting more and more costly (up to several hundred dollars depending on the application) while intermediate rebuild kits are very inexpensive and once you've done it, very simple to do. | These days alternators are getting more and more costly (up to several hundred dollars depending on the application) 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. | 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. | ||
| + | ==Rebuild your alternator== | ||
If you plan to rebuild your alternator, some easy steps to a DIY project are below. | If you plan to rebuild your alternator, some easy steps to a DIY project are below. | ||
| − | == Removal and clean up == | + | === Removal and clean up === |
* Disconnect the vehicle battery. If you have a charger put it on charge during the rebuild. This will help to improve battery life and minimize the load on the fresh alternator after rebuilding. | * Disconnect the vehicle battery. If you have a charger put it on charge during the rebuild. This will help to improve battery life and minimize the load on the fresh alternator after rebuilding. | ||
*Remove the alternator from the car and clean it thoroughly. | *Remove the alternator from the car and clean it thoroughly. | ||
| − | == Disassembly == | + | === Disassembly === |
*Using a scribe, witness mark the case halves so you can get them indexed properly when you re-assemble it. It can go 3 or 4 different ways. | *Using a scribe, witness mark the case halves so you can get them indexed properly when you re-assemble it. It can go 3 or 4 different ways. | ||
*Remove the through bolts so you can separate or halve the cases. | *Remove the through bolts so you can separate or halve the cases. | ||
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*With a fine emery or crocus cloth, burnish the brush pickups or (slip rings) on the rotor assembly until smooth and shiny. Emery dust is conductive so clean up your work when done. | *With a fine emery or crocus cloth, burnish the brush pickups or (slip rings) on the rotor assembly until smooth and shiny. Emery dust is conductive so clean up your work when done. | ||
| − | == Installation and inspection == | + | === 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. One may use a dab (small dab) of epoxy to accomplish locking the bearing race. This will prevent the race from spinning in the case. 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 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. One may use a dab (small dab) of epoxy to accomplish locking the bearing race. This will prevent the race from spinning in the case. 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 (if applicable). Lubricate the bushing as required. | * Install the bushing (if applicable). Lubricate the bushing as required. | ||
* 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 heavy paper clip with the brushes fully compressed into their holder. This will hold them off the slip rings while you insert the rotor into the end bell. Remember to remove the paper clip or drill before reinstalling the battery or a short could occur while removing the drill or paper clip. | * 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 heavy paper clip with the brushes fully compressed into their holder. This will hold them off the slip rings while you insert the rotor into the end bell. Remember to remove the paper clip or drill before reinstalling the battery or a short could occur while removing the drill or paper clip. | ||
| − | * Before reassembling the end bells to the body, inspect the stator windings. You are looking to make sure there is no worn insulating paint, | + | * Before reassembling the end bells to the body, inspect the stator windings. You are looking to make sure there is no worn insulating paint, aka [http://www.glyptal.com/ "Glyptal"]. Also, where the windings terminate, check that there is no melted or splattered solder, and no cracked solder joints. If needed, ohcheck the resistance with an ohm meter, but these usually last practically forever. |
* Align the witness mark you scribed into the body during dis-assembly, install the end bells to the body and properly 'clock' it for your application. Be sure the end bells are straight, and (if needed) gently tap the bearing half end-bell with a mallet. Secure with the bolts. | * Align the witness mark you scribed into the body during dis-assembly, install the end bells to the body and properly 'clock' it for your application. Be sure the end bells are straight, and (if needed) gently tap the bearing half end-bell with a mallet. Secure with the bolts. | ||
* Lastly, spin it up by hand, in both directions, and ensure it spins free and quiet. Inspect the front fan blade for damage, and reinstall on the car. | * Lastly, spin it up by hand, in both directions, and ensure it spins free and quiet. Inspect the front fan blade for damage, and reinstall on the car. | ||
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[[Image:image03.jpg]] | [[Image:image03.jpg]] | ||
| − | == Inspect the hardware == | + | === Inspect the hardware === |
If you notice white powder on the brackets or hardware, you have electrolysis going on (mounts are aluminum and hardware/engine is steel... what were they thinking??) Remove and media or water blast them. | If you notice white powder on the brackets or hardware, you have electrolysis going on (mounts are aluminum and hardware/engine is steel... what were they thinking??) Remove and media or water blast them. | ||
If you are a "stickler" install a copper braid strap from a good ground on the alternator to a good ground on the engine block. This will assure good electrical performance and eliminate mounting brackets from being important to the electrical ground path. | If you are a "stickler" install a copper braid strap from a good ground on the alternator to a good ground on the engine block. This will assure good electrical performance and eliminate mounting brackets from being important to the electrical ground path. | ||
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