Has anybody attempted to DIY their Alternator Rebuild?

[2002Scoob]

10 hours ago, TobyB said:

Yes, you can REPAIR a broken alternator.

 

REBUILDING one would involve completely stripping the coils off of it,

rewinding, relacquering, and so forth.

 

Tru.... Yah, 'Repair' is a more applicable term. 

 

Even more honest would be 'doing just enough to get it working again and nothing more'

Edited September 10, 2019 by 2002Scoob

[2002Targa]

It's not an 02, but if you have an early 318 upgrade, close enough!!

https://www.youtube.com/watch?v=eLgjyJBvYs4

[Buckeye]

I have repaired a couple of them in last 2 years and they are not difficult to work on.

You need tell us what is doing or not doing. That is important.

You could open it up and examine brushes and slip ring diameter. You know slip ring minimum dia. should be 31.5mm

In my case both alternators worked on needed new bearings, brushes and slip rings.

[2002iii]

Disassemble slowly and carefully on a good clean work space taking lots of pictures. Clean inspect and replace all wear parts and use your pictures to reassemble. Then upload pics and short write up so we can all benefit. It really isnt that hard, if you can change your oil you can rebuild an alternator. Also if your alternator is original the regulator is external ( silver box with yellow stripe behind driver's headlight).

[thinksound_mike]

17 hours ago, TobyB said:

320 alt in everything.  Well, or a Chevy Sprint...

 Toby,

 

You installed a chevy Sprint alternator in a 2002? Any special brackets needed? Internally-regulated or no?

 

Mike

[2002Scoob]

I have repaired a couple of them in last 2 years and they are not difficult to work on.

You need tell us what is doing or not doing. That is important.

You could open it up and examine brushes and slip ring diameter. You know slip ring minimum dia. should be 31.5mm

In my case both alternators worked on needed new bearings, brushes and slip rings.

 

Current symptoms are 14v at idle, but anything over 2.5k and the current drops to 12v and the ‘L’ light will lightly glow.

 

Just started the last drive where I went to Karlsruhe to buy an e12 rear subframe, and there’s a tunnel along the way where I turned on my headlights. Stopped a few Km south of it to take a piss and have a coffee at a rest stop and forgot to turn them off, and 15 min later she wouldn’t start.

 

Jumped it, and drove another hour home, and noticed in-town the light dimly lighting up when pulling away from a stop.

 

That’s when I used the 123 dizzy’s Bluetooth app to check the voltage at different RPM’s, and saw the voltage drop which was triggering the dash light.

 

Took it to a trusted shop that confirmed an alternator/charging issue, but they weren’t able to source parts for a repair in-time for a trip a few days later.

 

I did not know about min. shaft diameters, but now I do I’ve have it on the bench next week-headed to Berlin for the weekend and then hoping to spend a few days at the Frankfurt Auto Show next week.

 

 

Sent from my iPhone using Tapatalk

[Buckeye]

Symptoms described let me believe carbon brush and/or slip ring are worn out. After returning from mini vacation go thru  following procedures obtained from Manual Service book and before you take to bench. Test results from procedures should confirm to actual components conditions after disassembly.

 

 

 

[Sahara 72 2002]

On 9/9/2019 at 12:18 PM, albatcha said:

I had a real hard time finding a source for all the parts needed to fully rebuild the alternator. What I ended up doing is I found a good deal on a rebuilt one by Remy with no core charge for like $50 on ebay. I just swapped all the new internals from the rebuilt one into the old housing.

 

I'd be glad to do the same thing, but in looking around on eBay I'm not finding the Remy you mention. Any chance of sharing the search terms or a listed item? 

 

Also, not finding any 2002 alt parts on the 3 supplied links, what am I missing? 

Thanks!

[Einspritz]

1 hour ago, Sahara 72 2002 said:

Also, not finding any 2002 alt parts on the 3 supplied links, what am I missing?

 

Sorry, but you have to do the work, or e-mail them to see if they have the parts you need.

 

You need to find the bosch number for your unit, then look up parts for that specific model.

 

easy.

[2002Scoob]

Welp. lil' update, and a new question.

 

I gave up on my OG alternator, that side-bolt was frozen solid, and so was the front nut holding the pulley/etc. together. Like, rock solid. More hassle than it was worth.

 

So I opted to spend money with the risk of unknown hassles, and bought a 'rebuilt' alternator from an enthusiast online that had been sitting on his shop shelf for the last 15 years. A gamble, but a relatively cheap one.

 

Well, it arrived, and this little beauty sings like a bird. But only when rotating in it's forward rotation. Back-spinning is silent. 

 

Check-it. 

 

 

Questions/Thoughts.

 

It sounds like it's coming from the back of the alternator-

-Is it possible that new brushes or other components need to bed-in, and that little birdy will fly away after a while?

 

Or, if it's a bad bearing, It could be as easy as disassembling adding some bearing grease, and bobs-ur-uncle. 

-But why would a bad bearing only sing in one direction? Logic would tell me it would squeal in BOTH directions. 

 

Or, is it something I haven't thought of? 

 

Fun Fun. 

Edited October 8, 2019 by 2002Scoob

[tech71]

Install it, see if it works. The worst that can happen is it won't. 

[Vicleonardo1]

Hey Scoob,

Just because I lack any mechanical skills whatsoever. From my standpoint (and failing memory) a good auto electric/alternator shop for a rebuild wasn't that expensive. I do understand the joys of DIY, it can be pretty cool. But for me trying to do it on my own would take away too much fun driving time-as it may be disassembled for quite some time due to lack of free time to work on it. . I look at it as paying for some free time(=more 02 driving time),  plus their expertise and whatever limited guarantee that comes with it. 

My non-DIY $.02

Cheers! 

[2002Scoob]

2 hours ago, tech71 said:

Install it, see if it works. The worst that can happen is it won't. 

 

Well the thing is, the guy I bought it from is totally cool in taking it back. But I don't (and he doesn't as well) want me to throw it in, drive it around a bunch, roach the internals, and then send him back a totally busted alternator. 

 

2 hours ago, Vicleonardo1 said:

Just because I lack any mechanical skills whatsoever. From my standpoint (and failing memory) a good auto electric/alternator shop for a rebuild wasn't that expensive.

 

Bigger issue is I live in a pretty small German town, and there's no specialist for alternator repair here that I've found. I'd have to venture out a ways. Most mechanics like to deal in core-parts replacements. 

 

On-top I'm just not stoked about putting a ton of money into this, as I've got bigger plans/financials to deal with. 

 

The PO has given me the trust and go-ahead to crack it open, which I'll most likely do. The unit looks seriously cherry, so it should come apart easier than the OG unit. 

 

But I love to tap the brain-trust here first beforehand. :)

[PaulTWinterton]

49 minutes ago, 2002Scoob said:

The PO has given me the trust and go-ahead to crack it open, which I'll most likely do. The unit looks seriously cherry, so it should come apart easier than the OG unit. 

 

First off, I've had issues with disassembly of alternators as well.  It's as if they don't want you to open it.  Slot-head bolts? WTF!  Easiest head to strip.  

 

I visited an auto-electric shop and took note of how they do it.  AIR TOOLS!  Impact drivers with the correct head to fit the slot perfectly and a socket for the pulley bolt.  No problemo.

 

A large screwdriver to wedge the pulley so it doesn't turn while using the air tool.

 

I've had better luck since using the correct tools.

 

Concerning your "singing" alternator.  I'm asking the FAQ: is their a lubricant that you can spray on electrical components that won't effect the circuits, but will lubricate where needed?

[Buckeye]

Before you split that alternator you could remover the nut, pulley, key and fan blade then drop small amount of oil of shaft bottom to see if noise goes away.

Mark a line on both half in-line to each other before taking apart