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You should wind up with this setup:
(top left to right)
Rear Casing, brush springs, coil.
(bottom left to right)
Heat sink, regulator, battery post, and 3 coil nuts....(one washer...I lost two). |
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The reason I said totally loosen but don't remove screws is it's best to just
leave them in the slot and wrap masking tape around them. No lost screws and no wondering where they are.
Also put springs, washers and any loose nuts (coil if you don't rethread them onto their origin) on a piece of
tape to keep them in place. |
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I used a sanding taper and my dremmel from Eastwood Company to knock the cast
off the hard to reach spaces like the grooves and the back. I sanded all the easy reach places with my Trizact
Expander wheel, also from Eastwood.
Then polish the entire case as outlined in Part I. |
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I masked off the coil edges and painted with semi-flat black so the exposed
surfaces would be nice and black for contrast. Then also repainted the pulley and brace.
I used some scotchbrite to scuff some surface junk off of the internal windings also. |
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Next is reassembly. It is not hard. Slap some grease in the bearing and pay
attention to the Trick of all tricks.
When you go to reassemble the front to the back you have to have
a way to hold the brushes in their slot against spring pressure. Cut a piece of coat hanger, push in the springs,
then brushes and run the hanger wire through the guide hole. |
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Here is another view. It may take a few times of trying to get this act together.
Put the top brush in, and use the hanger to hold it in as you mount the bottom brush in, then run the wire all
the way through. It will come out the back of the alternator. |
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Now turn the alternator over and here is your wire. After you have secured
the front and back cases with the four bolts and everything is lined up. Just pull the wire out and the brushes
snap up to the armature.
Note: It is very easy
to get the front case mounting 180° off.....pay attention to details on disassembly. |
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I remount the pulley and get ready to remount the mount bracket. |
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The back of the housing turned out way better than I expected thanks to the
sanding taper. |
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Here is a side view that shows why I painted the exposed coil area black. You
could have also hit it with a buffing wheel for high gloss but I wanted some contrast. |
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| Bingo Baby.....investment about 4 hours solid work over a two night period
and zero dollars. Don't be scared of your alternator. It is a simple device. Most of the time that one goes bad
it is either bearings, or regulator. You will know it if it's the bearings. And the regulator is very easy to replace
for $10.00. Now you know why they always insist on your core exchange. It's an easy fix. I must say this was one
of the easiest and most rewarding car projects I have ever done..........have fun. |
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[ Back
to Part I ]
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