Alternator fail

[jgra1]

hi chaps, my boxer alternator failed on way home last night, at Stonehenge (a common breakdown place for me now )

the light came on, and I got to the next service and checked voltage.. no charge..

an AA chap was nearby and said no don't go any further, back of truck etc.. then realised I knew a fair bit about the van, measured my current draw at around 9 amps, running.. with that in mind plus the fully charged spare battery (leisure) we agreed I would get home ok, which I did..

I have never taken an alternator apart, but have bought a NOS reg and brush pack just now on ebay, is this a simple bolt on fix to get the unit back up and running? presume alternator off van, over to workbench, and see how I get on?

TIA
John

[Hell Razor5543]

It depends on the level of access you have to the alternator, and the alternator itself. I have replaced the brush pack on one on my BX, and it was easy, but access was very good (so I could do it in situ).

[bobins]

I've completely rebuilt a JCB alternator in the past - it was 50% alternator and 50% mud so had to come down to component level. It needed 2 soldering irons held together to melt the solder, but apart from that, it's just big boys Lego Make sure the brushes are held right back when you stick it all back together so they don't get caught.

[citro6hydra]

Hi John,
Assuming the regulator/brush assy is the correct one for your alternator it should be a very easy and straightforward fix, am not familiar with the boxer but alternator off the vehicle is probably easiest if access is not that good, also check the condition of the slip rings, even if these are not brilliant you could do the repair to get mobile again and asap get the slip rings machined or replace them.

Depending on the make of alternator the slip rings could be bronze or steel, carbon brushes for bronze and bronze / carbon for steel (similar material to starter motor brushes) but if the reg/brush assy is the correct one then then this should not be a problem please let the forum know how the repair goes.

[Peter.N.]

I called out the AA a few years ago, my own fault I left the lights on (Peugeot 406 again) the lights don't go off when you turn off the ignition unless it's on 'auto'

They sent a garage out, the mechanic insisted I needed a new battery, he even connected a meter across it to show me, I don't know whether it was a con or his knowledge of car electrics was minimal but the battery was reading well low with the engine running even though everything on the car was functioning normally, I hate to suggest his meter was deliberately miscalibrated but I declined the offer of a battery and needless to say when I got home and checked it I had a reading of 14.4 volts and never had any more trouble.

Peter

[jgra1]

many thanks all! will keep you posted, will grab alternator off van I think as it's quite easy.

blimey Peter, that is a bit naughty..

John

[jgra1]

got the alternator off today, the brushes are well worn, and I suspect the slip ring (outer/upper) is far gone too.. so will have a go at my first ever alternator repair! may get to it Sat or Sun..

[Hell Razor5543]

Good luck with it.

[van ordinaire]

Sense of satisfaction aside, for the cost of a s/h alternator, is it worth it?

[jgra1]

i know what you mean Van.. I have never bothered before.. but £11 versus an unknown used unit..

to be honest the boxer etc - whilst sharing many parts with the 2.0Hdi - has a few oddball parts for it only, so it seems... couldn't find much about for less than £100 when I had a quick look last week..

anyway, all back together and all voltage back.. so, 2 brushes, a new end bearing, and a new slip ring.. wasn't too bad at all.. a couple of useful you tube vids for rebuilding a Valeo helped a lot.. but anyone could do it

[van ordinaire]

Well done, a useful skill acquired & a good saving as a nice little bonus.

Actually, I'm quite surprised you can get the parts as nobody (in this country) seems to do that sort of thing anymore - or, indeed, repair anything.