In this post I admit a failure. Not sure this post will help anyone but I wanted to discuss it.
Recently my alternator died. I asked a lot of questions about how to test an alternator but didn't get any specific answers.
I then watched a bunch of videos on youtube (to be listed below when I get a chance) that gave me enough to go on.
In the end I tested :
1) that there were no shorts in any key pieces.
2) my diodes were fine.
3) slip rings worked but were physically damaged.
In the end I tested everything except for the voltage regulator so I ordered a new one, popped that one and put it back in the car. With that done, my alternator worked. However, as noted in #3 above, my slip rings were damaged. One of the brushes had cut a significant groove in one of the slip rings so I decided to replace the slip rings.
Since I was doing that, I figured why not replace the bearings as well.
That led to several special tools (to remove alternator clutch) and WAY too many hours taking everything apart and replacing things.
Major hurdles were:
1) every phillips head screw except for two stripped out. I had to drill/tap those.
2) one of the bolts holding two halves of alternator broke. Figured out a way to get rest of threaded bolt out without having to drill it out.
3) removing front bearing required cutting bearing shell off and cracking it apart.
4) I did something stupid which damaged threads on pulley end of alternator and that took at least an hour if not more to grind off and manually repair threads with small file.
5) I really need a workshop.
But in the end, replacing bearings and slip ring was quite easy.. I tested that the slip rings were put on right (no contact with frame/core of alternator) and put everything back together.
I installed the alternator, hooked up the battery and instantly felt a wave of depression when I heard a pop and saw a small column of smoke rise up from the alternator. Started car up and sure enough, it wasn't working and idiot light on dash confirmed I messed up somehow.
I ended up ordering a Bosch alternator from FCP because I had already sunk WAY too many hours into "repairing" my alternator.
A seemingly simple (although really time consuming) job just ended in failure. I didn't really mind that I failed at this job but what really drives me nuts is I have no idea what I did wrong. I had to turn in my dead one for a core charge so I don't have the old one for any diagnosis.
The only thing I can conclude is that somehow I introduced a short in the alternator. I'm not even sure that's the right phrase. Just disappointed in not knowing what I did wrong.
Knowing what I know now, I'm not sure I'd try to rebuild an alternator again. The tools and parts cost me $70-$80 (clutch tool, bearings, slip rings, new bolts and screws, voltage regulator).. A rebuilt bosch alternator was $225.. And if I priced out my labor, I definitely spent way more than just buying an alternator.
However, I didn't do this job to save money. I wanted to learn about alternators. And that I did.. not sure what I learned thought.
-A
