Alternator Rebuild

[Java]

Since my Jeep has been having age and wear related issues this year I'm considering getting ahead of the alternator (and power steering pump and maybe injectors- future threads) by rebuilding it. A can of electrical cleaner and a rebuild kit from NAPA is about $40.00- anyone done this??

kit example- http://www.ebay.com/itm/Cherokee-4-0-2001-Denso-Alternator-Repair-Kit-121000-3780-/231245564621?pt=Motors_Car_Truck_Parts_Accessories&hash=item35d74f4acd&vxp=mtr

how to:


https://www.youtube.com/watch?v=LqvTHJVQU5g&list=UUUhHcfitC7MYvijPvZTV0rw

[eck55]

I have done a couple alternators and starters. Pretty easy just watch getting pinched by the housing as the magnets may pull it down hard. Make sure the bushings/bearings are lubed. Clean all the terminal connections.

[ExplorerTom]

I tried to rebuild 1 alternator. Didn't work out for me. I couldn't get one of the bearings out.

[Patrolman]

I have actually rebuilt 2 Toyota model alternators, including replacing the stator with an upgrade 90 amp unit. Works great and easy to do. I followed these instructions, which may be similar to yours. See if you can upgrade the amps if you are going through the trouble of the rebuild. Well worth considering.

http://www.4x4wire.com/toyota/tech/alternator/

[Java]

At about 1:50 in the video he talks about whether you rebuild or repair, the difference is really bearing replacement. My bearings are fine, the whole alternator is working fine, its just 8 years old, cruddy and full of dirt so while it's out for cleaning I'm doing the repair. I ordered a set for it like this for about $20.00 and will keep the parts I take out as spares.

http://i.ebayimg.com/00/s/MTYwMFgxMjAw/z/u~oAAOxyoVZTIkr1/$_57.JPG

[Patrolman]

If you feel adventurous, on the old set of brushes, you can replace just the brushes for about $2.00. Then you already have a brand new set for spares. All you need is a solder iron to remove/replace them. Personally, I have never heard of bearing failure on an alternator, so you will likely be good to go!

[glacierpaul]

:thumb: good luck Paul! This reminds me I need to upgrade my oem YJ alt. for a Mean Green High Output. Should help me on my plowing duties.

[Java]

this was super easy, it took about an hour and a half including r/r. I can't believe they get $150.00+ with a core for remans at the store, this cost about $30.00. My alternator passed the bearing test in the video so I just replaced the brushes and connector, what the guy in the video calls "repair" vs. "rebuild". A kit with bearings is about $40.00. I also used a $4.99 can of cleaner, compressor and wire brush to get everything pretty. My brushes were about 2/3 gone, but still alive, so I cleaned out what I replaced and am putting it in my spare parts. I got a lot of dirt out of it, and the output went up slightly according to my dash gauge. Should give me another 8 years of service now! :thumb:

[Patrolman]

Congrats! That is such a simple job, you are right, it is silly that anyone buys a "rebuilt" alternator. If I don't have a spare, I will buy a used one to rebuild on the bench and have ready. Then I know it has been done right and what was put in it. Same thing with starters.