Anymore , Alternators are getting more and more costly (up to several hundred dollars depending on your issue..) ..while intermediate rebuild kits are very inexpensive and Once you've done it..Very simple to do
Assuming the Alternator didn't burn up electrically , (windings melted down) these simple steps will net you a very reliable operating Alternator ..and save you about $100 bucks in the process..
If you plan to rebuild your alternator...Some Easy steps to a DYI project
Removal and Clean up
* Remove it from the car
* Get about 2 or 3 cans of gunk, go to the coin wash, spray it with the gunk..let it soak 5 minutes..THEN set the wash to degrease, spray that for 5 minutes..Then rinse for 5 to 10 minutes..Allow dry time OR better yet air blow dry..
Disassembly
* Mark the case halves so you can get them index properly when you re-assemble it. It can go 3 or 4 different ways.
* Halve the cases
* Remove the brushes, brush holder/followers (depending on kit)
* Remove the Bearing
* Remove the bush (depending on kit)
* Remove the regulator and install the new one.
* Remove the rectifier Diodes and install the new ones.
* With a fine Emery or Crocus Cloth, Burnish the brush pickups or (Slip rings) on the rotor assembly until smooth and shiny.
[edit] Installation and Inspection
* Install your new bearing, but before you do..get a SMALL sharp punch, carefully put a dimple in the race each 1/3 rd the way around. This will prevent the Bearing from EVER spinning in the race..is a tiny bit harder to put the cases back together, you have to tap the halves with a rubber mallet.
* Install the bushing. (depends on kit)
* Where the brushes are at the rear end bell, there should be a small hole that goes through to the brushes..insert a #40 drill bit or paper clip with the brushes fully compressed up..this will hold them off the slip rings while you insert the end bell.
* Before reassembling the end bells to the body, inspect the windings..you are looking for no warn insulating paint, or glypt, and where the windings terminate, no melted or splattered solder or cracked joints If needed, Ohm the windings out..but these usually last forever..and if they failed before..you'd know it..
* Install the end bells to the body and properly "Clock it for your application, be sure the end bells are straight..and (if needed) tap the bearing half end-bell with a mallet..and secure with the bolts..
* Lastly spin it up by hand and insure it spins free and quiet..Inspect the front fan blade, and reinstall on the car.
Inspect the Hardware
If you notice the brackets or hardware is power white, remove them and media or water blast them , you have electrolysis going on there (mounts are aluminum and hardware/engine is steel..What were they thinking??)
Get some electrical bonding paste for aluminum wire..and coat the bolts, and mounts anywhere they touch steel..
