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#Post#: 73783--------------------------------------------------
Reconditioning an alternator
By: espacekiller Date: September 7, 2013, 6:53 pm
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This is a brief guide on how to recon your alternator yourself,
it seems alternators in Land Rovers often suffer with mud water
etc. In my experience many recon alternators are not that great,
they seem to do the bare minimum to get them working again long
enough to make it out of warranty, then clean them up well so
they look new and send em back out.
You can do much better yourself for less money, i am no expert
but have done several of these with good results, better than my
last £70 recon unit which lasted 8 months.
This is a more 'modern' unit from a 200 tdi engine.
Mucky alternator, clean the outside so we can see what we are
looking at it does not need to be perfect.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3156_zps381dd521.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3156_zps381dd521.jpg[/img][/URL]
You need the number off it, this is an A127 65amp. You will need
this when searching for parts.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3158_zpsa97e0f1f.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3158_zpsa97e0f1f.jpg[/img][/URL]
Remove the covers and start stripping it down, take photos so
you can put it back together correctly.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3160_zps49b3a7cd.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3160_zps49b3a7cd.jpg[/img][/URL]
This the Voltage Regulator/brush pack and the scource of 90% of
issues with alternators, as can be seen this has been wading,
the mud has dried jamming the brushes in to their slots, this
will not work. This is probably the most likely fault on a land
rover. They can also burn out the regulator circuit if there is
a fault shorting the alternator wiring to ground.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3183_zpsd3ea176d.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3183_zpsd3ea176d.jpg[/img][/URL]
A quick squirt of WD40 and the brushes are free this would now
work perfectly fine, worth knowing in the field a blast of clean
water or spray oil may well flush out the brushes and get you
home. As can be seen the brushes are fairly worn so in this
case we will replace them so it will remain hassle free for a
long time to come.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3187_zps8fd8ffa5.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3187_zps8fd8ffa5.jpg[/img][/URL]
Remove the end cover, you might need to do some careful levering
to free the case, be very careful you do not dammage the copper
coils.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3188_zpsc64027e2.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3188_zpsc64027e2.jpg[/img][/URL]
End cover removed we can now see the diode pack, this is solid
state and reasonably reliable usually.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3189_zpsbf3cf9a8.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3189_zpsbf3cf9a8.jpg[/img][/URL]
Fully dismantled
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3190_zps8720a5d5.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3190_zps8720a5d5.jpg[/img][/URL]
We can now see the slip rings, as can be seen the one on the
left is serviceable but the one on the right is worn beyond an
acceptable level in my oppinion, for this alternator to be
reliable we need to replace the slip ring, in a cheap recon unit
this would be reused which would reduce the lifespan of the unit
vastly.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3193_zps350ee638.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3193_zps350ee638.jpg[/img][/URL]
Refit the stator and test for play in the bearings, if you need
to renew them the bearing number should be stamped on the seal
although it is sometimes on the outer case of the bearing. In
this case the bearings where in very good order so where reused.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3196_zps18cf1d67.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3196_zps18cf1d67.jpg[/img][/URL]
New slip ring and regulator pack £14 on ebay, it was cheaper to
buy a whole reg pack than the brushes alone? But the brushes can
be changed you usually need to drill out the old connections or
de solder them and then re solder new ones in. I will keep the
old Reg in the vehicle as a desert spare.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3294_zpscf3bb58d.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3294_zpscf3bb58d.jpg[/img][/URL]
Removing the old slip ring, de crimp or de solder the 2 wires be
very careful not to dammage the wire it has a thin veneer of
varnish for insulation! Side cutters open up a crimp nicely as
shown.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3301_zps144f89f5.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3301_zps144f89f5.jpg[/img][/URL]
Wires removed, test with a meter and make a note of which slip
ring feeds which wire (ie top or bottom ring) and label the
wire.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3302_zpsf3f1aab9.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3302_zpsf3f1aab9.jpg[/img][/URL]
Cut down the old ring close to the shaft but try not to dammage
it, junior hacksaw is good.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3304_zps286bd23f.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3304_zps286bd23f.jpg[/img][/URL]
Fit an adjustable to the flat and use it to turn the remainder
of thering to free it off the shaft.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3306_zps3711ba4d.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3306_zps3711ba4d.jpg[/img][/URL]
Removed
[URL=
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Press on new slip ring using a socket of appropriate size, make
sure you get it the correct way round as labeled earlier.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3322_zpsd1ab1fd8.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3322_zpsd1ab1fd8.jpg[/img][/URL]
Pressed on
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3324_zpsd56b4613.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3324_zpsd56b4613.jpg[/img][/URL]
Clean the varnish insulation from the section to be crimped to
allow a good connection and for the solder to take.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3331_zps6064b963.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3331_zps6064b963.jpg[/img][/URL]
Soldered
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3332_zpsa4677e79.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3332_zpsa4677e79.jpg[/img][/URL]
A few bits cleaned up and
painted[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3337_zps8312657a.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3337_zps8312657a.jpg[/img][/URL]
All cleaned up and ready for rebuild, when you bolt the case
back together you may need to adjust the position of the ends by
tapping with a hammer to prevent the stator catching before
clamping the ends together tight.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3347_zps811e55a2.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3347_zps811e55a2.jpg[/img][/URL]
Rebuild finished ready for many hours of hassle free service
:rolleye0012: well probably far better than most recon units.
[URL=
HTML http://s965.photobucket.com/user/my05pjn/media/atlernator/DSCF3359_zpsd3a01aa1.jpg.html][IMG]http://i965.photobucket.com/albums/ae131/my05pjn/atlernator/DSCF3359_zpsd3a01aa1.jpg[/img][/URL]
#Post#: 73796--------------------------------------------------
Re: Reconditioning an alternator
By: Gozo_Joseph Date: September 8, 2013, 2:47 am
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hi nice and interesting post :)
mine doesn t see much wading so kind of lasts a bit longer
:rolleye0012:
while i am here, is that magneti marelli also good on a series 3
diesel I.E. do i need to mess about with wires and fuses? the
16ACR is rated at 35amps.
nice work
joseph
#Post#: 73797--------------------------------------------------
Re: Reconditioning an alternator
By: Arjan Date: September 8, 2013, 2:48 am
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This is an awesome post :thumbs:
Thank you very, very much - goes on the workshop bible list !
#Post#: 73800--------------------------------------------------
Re: Reconditioning an alternator
By: parksy64 Date: September 8, 2013, 2:57 am
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:thumbs: :thumbs: :thumbs:
#Post#: 73804--------------------------------------------------
Re: Reconditioning an alternator
By: clunk Date: September 8, 2013, 3:08 am
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Excellent post sir, :thumbs: The Magneti on Guzzle was giving
me the red light from near Doncaster to LATP. Luckily I found
a working replacement in the auto jumble. Was going to bin the
old one, but I shall attempt an overhaul. If I cock it up
nothing lost. :thumbs:
#Post#: 74824--------------------------------------------------
Re: Reconditioning an alternator
By: estwdjhn Date: September 15, 2013, 1:48 pm
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One point not mentioned ^^^ that's worth noting.
The cases are assembled handedly - so the alternator tension
adjusts by swinging either left or right of the mounting bolt.
Disco variants of the these alternators are handed one way,
Defender ones the other. It's dead easy to swap them between the
two options to suit your mounting brackets (fwiw series 2.25
alternator brackets are handed the same way as defender ones)
without dismembering the whole thing - just undo the three long
bolts through the alternator, and turn the front face plate to
suit.
Top guide BTW - probably about time I had a go at fixing one,
rather than just raiding dead disco's for spares!
#Post#: 75137--------------------------------------------------
Re: Reconditioning an alternator
By: mr.scruff Date: September 18, 2013, 10:04 am
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Superb.
SAVE MONEY WITH OLLR
#Post#: 75148--------------------------------------------------
Re: Reconditioning an alternator
By: Drew Date: September 18, 2013, 12:21 pm
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This topic could be of especial interest to Stig, currently
marooned in Worthing, on his way to France :smile1
#Post#: 75172--------------------------------------------------
Re: Reconditioning an alternator
By: chally2 Date: September 18, 2013, 2:48 pm
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Great post. I'm sure that will come in useful in the future.
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