1989 240DL - Is it possible to rebuild a Bosch starter?

dannym · Post by **dannym** » 17 Aug 2009, 11:21

Like the title says. Has anyone ever tried to rebuild a starter?
I have a Bosch dealer near me if I need parts.

Danny

Post by **billofdurham** » 17 Aug 2009, 11:33

Anything is possible - if you can get the parts. Check with your Bosch dealer to see if he can supply what is needed. Bear in mind that if you are looking at replacing more than the brushes and springs it may be cheaper to buy a reconditioned unit which will have a warranty.

Yes, I have the instructions if you need them.

Bill.

dannym · Post by **dannym** » 18 Aug 2009, 05:13

Instructions would be awesome!

Post by **billofdurham** » 18 Aug 2009, 12:49

The instructions are for a typical Bosch starter motor (Volvo's words, not mine). I have done several rebuilds on various makes of car with Bosch motors and they all follow the same pattern.

240 Bosch starter 1.pdf: (674.81 KiB) Downloaded 831 times

240 Starter motor 2.pdf: (387.28 KiB) Downloaded 478 times

240 Starter motor 3.pdf: (749.83 KiB) Downloaded 467 times

Bill.

dannym · Post by **dannym** » 19 Aug 2009, 12:36

I'm so retarded...I'm not trying to rebuild a starter I'm trying to rebuild an alternator!

Would you happen to have instructions to rebuild alternators?

Thanks for the starter info, I'll save them for a rainy day!

Danny

Post by **billofdurham** » 19 Aug 2009, 12:59

Back to the question "Is it possible......?"

Yes.

240 Bosch alternator2.pdf: (240.04 KiB) Downloaded 215 times

Bill.

dannym · Post by **dannym** » 20 Aug 2009, 05:53

Thanks again!!

dannym · Post by **dannym** » 20 Aug 2009, 15:14

Look what I was able to get my hands on!

Alt breakdown.pdf: (1.56 MiB) Downloaded 270 times

Danny

dannym · Post by **dannym** » 21 Aug 2009, 13:02

Here's a price breakdown I got from Bosch.....

The part numbers you will need are as follows:
1 120 905 004 – which supersedes to a 1 120 905 533 000 - factory Deep-Groove Ball Bearing $ 13.66 each
1 120 905 026 – which supersedes to a 1 120 905 102 - factory Deep-Groove Ball Bearing $ 14.48 each
1 127 320 712 – Germany has stock on this item Rectifier $149.06 each
1 197 311 022 – which supersedes to a 1 197 311 028 – factory EL Field Rheostat $ 29.52 each
0 290 800 036 – factory Suppression Capacitor $ 11.68 each
1 127 011 020 – factory Parts Set Rotor $ 10.35 each
1 127 011 070 – Spain – 6 month lead-time Parts Set Clamp, B+, D+ $ 23.14 each
1 127 014 022 – factory Carbon-Brush Set $ 5.08 each

The individual diodes are not sold separately. You would need to purchase the whole rectifier.
The whole alternator part number 0 120 469 786 is an inactive part with Bosch.
It does cross to a Bosch Reman number of a AL157X which is available at the factory. Your cost would be $154.18 with a $75.00 core charge. We are a distributor for many other electrical lines as well. I have attached a copy of our line card for you. We can probably cross this to another vendor’s part number and provide you with a new alternator at a much lower cost than fixing your existing unit.

That sucks!!

Guess I'll be buying a new one!

Danny

Post by **billofdurham** » 21 Aug 2009, 15:23

FCP - $150.00 and no worries about what goes where.

Bill.