Anyone rebuilt their alternator?

[steved]

At 245k, figured to do a batch of preventative maintenance. Seeing the rebuild kits for the alternators on Geno's.



Anyone tried rebuilding these alternators before using the Geno's kit? I've rebuilt older alternators before, is there any tricks to these?

 

[JBallou]

Should be the same as a standard alternator. May have to use a small stiff wire to hold back the brushes for reassembly.



The kit may have some basic instructions, otherwise replace the parts that they give you in the kit. Make sure the armature is smooth, etc.

 

[steved]

I figured they might have some minor directions... its been a lot of years since I rebuilt an alternator, didn't know if there were any changes since the early 80s.



The kits (pictures on Geno's site) look simple enough, three parts: two bearings and a brush set. Guess I'll place the order, and see what kind of trouble I can get myself into...



Thanks!

 

[Kry226]

Steve, be sure to report back on your results. Thanks in advance.

 

[steved]

Well, I researched it a little; and all the threads indicate the pieces the brushes ride on typically wear to the point that the alternator is beyond simply brushes and bearings.

So I decided to buy a NEW alternator...

Diesel Starters & Alternators 100% New Great Price

These guys are recommending a 160 Amp Denso replacement, not a Bosch. They claim they have better results with the Denso... supposedly a direct bolt in. I will find more out tomorrow... cost is $270 shipped, which I don't find bad for a completely new (not reman'd) alternator.

 

[AABEN]

But it is a lot cheaper to rebuild. I have rebuild a lot of them and they out lasted the time that I keep the truck.

 

[steved]

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[steved]

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[steved]

I received my alternator from Nations, brand new 160A Denso (not a Bosch) complete with new pulley installed. While the Bosch is OE alternator, this Denso was a direct replacement with two minor differences... the field plug and positive stud are clocked slightly different (but made absolutely no difference). Took less than 30 minutes to swap. I highly recommend Nations, they were very helpful and offer an excellent product.

Because I was curious to as the life left in my OE unit, I pulled the brushes out... you can see the previous pictures. The Bosch looks like it is rebuildable, and I'll either rebuild it for a spare, or rebuild it and sell it. The only thing I don't like about the rebuild kit is that there is absolutely no instructions... but they look simple enough.

Keep in mind, this OE alternator was still going at 245k, but the brushes look like they were at the absolute end of their life... there was no "push" when I removed them, indicating they were barely touching. And although it still spun smooth, there was something lightly rough... and replacing the alternator made the truck quieter, indicating to me that there was a rough/bad bearing.

 

[Bill Weber]

Doing a rebuild. Does anyone know how to split the case to get at the bearings?

I have removed the 4 bolts holding the case half's but they do not want to separate.

Bill

 

[HBarlow]

I had an Amish in Indiana rebuild the alternators on my '01 and '06, both with over 200k miles on them. The rebuilds were perfect and cost me approximately $100 on each truck.

 

[JFought]

i bought the kit. the problem i had was, i couldn't get the over run pulley of the alternator. its take a special tool. so i put brushes in.

but i need to fix it quick! its squealing now! gotta get it fixed!

Any help would be appreciated.

 

[PFranzese]

Found a writeup on another forum that shows the steps to rebuild.



Bosch Alternator Rebuild - Dodge Cummins Diesel Forum

 

[Prairie Dog]

Found a writeup on another forum that shows the steps to rebuild.

Bosch Alternator Rebuild - Dodge Cummins Diesel Forum

Thats not a link.

 

[Bill Weber]

Prairie Dog:There a link on the thread I started yesterday. Don't know how to place it here as a link. Thanks to PFranzese for finding it for me. Don't know if it will help much. Link author said to pry the case half's apart. No can do. Will try again with a pulley puller and it breaks something then so be it.

Bill

 

[JEnnis]

Bosch Alternator Rebuild - Dodge Cummins Diesel Forum