Rebuild an Alternator

Rebuilding an alternator is a fairly simple procedure, which anyone with basic automotive knowledge can accomplish. Although the construction of some brands will vary slightly, the basic anatomy of an alternator consists of the same components. Follow these steps as you learn how to rebuild an alternator.

Steps

1. Disconnect the battery leads.
2. Remove the air cleaner for easier to access the alternator.
3. Mark the placement of the electrical leads before removing them.
4. Disconnect the electrical leads.
5. Remove the vehicle's serpentine belt.
6. Remove the mounting bolts and familiarize yourself with their placement.
7. Pull the alternator out.
8. Remove the plastic cover from the back of the unit by unscrewing it.
9. Inspect the bearing. If it does not seem snug, or makes noise when it spins, it will have to be replaced.
10. Replace the bearing, if necessary, before moving on.
11. Undo the screw which holds the resistors in place.
12. Pay careful attention to the placement of each wire before disconnecting any.
13. Replace the rectifier by prying out the soldered leads and then undo the mounting screws.
14. Pull the rectifier out.
15. Install the new rectifier by replacing the mounting screws. Solder the lead wires to reconnect them.
16. Reinstall the screw which separates the rectifier from the brush assembly.
17. Replace the brushes by first undoing the screws which hold each brush assembly in place. Remove the brushes from their channels.
18. Clean the area of the armature shaft that the brushes contact.
19. Assure that the spring for each new brush is directly at the back, pushing into the brush slot. Install the replacement brushes.
20. Remove the voltage regulator by first removing the screw from the bottom brush assembly. Remove the screw that holds the lead into the grounding screw.
21. Install the replacement voltage regulator by replacing the screws mentioned in the previous step.
22. Use an ohmmeter to assure that the diodes are receiving the proper current.
23. Replace the plastic cover as well as both of the resistors.
24. Put the alternator back in the vehicle.
25. Reconnect the electrical leads assuring that you're installing them properly.
26. Replace the serpentine belt.
27. Reinstall the air cleaner and verify that the belt tension and mounting bolts are right.
28. Inspect the heat shield at the back of the alternator to verify that it is properly installed.
29. Reinstall the battery leads.

Tips

• You may find it helpful to take photos, or draw diagrams of, the electrical leads and mounting bolts. It is critical that they are properly reinstalled.
• When installing a new volt regulator, be sure to apply thermal grease to the back of the apparatus.
• It may be helpful to disconnect only one wire at a time in order to replace them correctly.
• Be careful not to over torque the post, which serves as the main lead, from the brush set. This could cause it to break.
• Alternator parts are all fairly inexpensive at your local auto parts store.
• Consult the owner's manual for the specifics about your vehicle's alternator brand.
• In some alternators, the rectifier will be found pressed into the rear half of the alternator's frame.

Related Articles

• Change an Alternator
• Check an Alternator
• Put on an Alternator Belt
• Respond When Your Car's Battery Light Goes On

Sources and Citations

• http://www.econofix.com/alt.html#arb

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