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Old 12-12-2010, 12:21 AM   #1
hkpierce
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Default Alternator Rebuild

Now that I have a dead alternator and no-where for it to go, I thought it might be rebuildable for something cheaper than a new one or a re-manufactured one. The bearings seemed good, and replacement brushes/rectifier set is available for $35-60 plus shipping:
Bosch Reg.JPG

Testing procedures for each of the alternator's components are available here: http://www.humanspeakers.com/audi/alternator.htm
A complete Bosch alternator repair instructions are available here: http://www.rangerovers.net/repairdet...haltrepair.htm

It is really easy to remove the cover plate and the brushes/rectifier. In my case it was clear that the brushes had a lot of life in them - and looking at the armature there seemed to be no problem:
PC111732.JPG

The pulley is another story. The reason the pulley is so expensive [about $94 at Europarts SD] is that it has some type of viscous clutch in it. On my new alternator, the pulley clearly could be rotated at a different speed from the alternator. The reason for the clutch is that when you turn off the engine, the alternator will not be slammed to a halt - the armature can slowly come to a stop. But on my pulley, it was frozen. So, from my viewpoint, replacing both the pulley and the bushing/rectifier set was not worth it compared to just buying a new one.

Plus, as the pulley has a clutch on it, you need a special tool that locks the pulley while you rotate the shaft. More expense. Also, the service manual indicates that different alternators have different splines requiring different tools. Who is to say getting one tool to work on this pulley would be the same required for the replacement pulley?
PC111727.JPG

All-in-all, not much economic sense, much less the time and labor, in rebuilding it if anything other than the brushes/rectifier need replacing.

Last edited by hkpierce; 12-16-2010 at 06:14 PM.
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Old 12-12-2010, 01:03 AM   #2
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Default Re: Alternator Rebuild

So glad you said something about that clutch. I was starting to wonder, when I had mine rebuilt the guy said the clutch was bad. Never heard of that, anyway he must get a better deal on prices I think he charged $112 total with brushes and rectifier. Little family business been around over 40 years . Oh my symptoms was a loud squealing I thought the bearings had gone out but when I took it off it turned and felt fine.
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Old 12-12-2010, 09:21 PM   #3
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Default Re: Alternator Rebuild

This seem like a good place to post a good method for breaking an alternator nut loose without having to clamp the pulley.

1st make sure what direction you need to turn the nut to get it off.

The place the alternator on a suitable surface, and be sure there is nothing impeding the rotor from spinning freely... like your clothing or fingers
or in the unlikely case that there is enough room to get the tool and socket into position while the alternator is still mounted in the vehicle just leave it place.

With the proper size socket to fit the nut installed on your air impact wrench just give a quick on/off shot to the trigger, and if the first try does not break it free just let the rotor spin down to a complete stop and try it again.

The weight/torque of spinning the rotor is enough to break the nut free without damaging the pulley or rotor.



This guy is needlessly risking his thumb!
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Old 02-07-2012, 01:29 PM   #4
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Default Alternator Rebuild

I bought a spare voltage regulator after reading reports (and hearing Win tell the story of Dave Spainís faulty (and expensive) alternator diagnosis that really turned out to me a faulty voltage regulator. Win tells me itís located inside of the alternator but itís a pretty easy swap. Iíve never done it.

If you want to skip all the research and saga to just buy one, skip right to the bottom for the links.

The first one I bought was NOT the correct one. I thank Win for suggesting that, at the price I paid, it might not be rated for 200 amps which is the output of our Westy Bosch alternators. A more common alternator in Sprinters of our year (2004) is 90 amps. Virtually all of the sites one can use to buy a replacement voltage regulator for a 2004 Dodge Sprinter 2500 will lead you to the incorrect voltage regulator rated at most for 90 amps (and will be near $50-60) BUT youíll NEVER see the amp spec at those sites or almost any other site. NOTE also in this price range of $50-60 one will find the correct regulator rated for 200 amps on eBay but they are not OEM parts! Iíll include these as sources at the bottom here but I opted to stay OEM Bosch.

It shouldnít have been this difficult locating the correct one but it was. The breakthrough came using the P/N Dave S gave me for a regulator his dealer replaced in his Westy. I took that part number and the incorrect voltage regulator that I had brought to my dealer. Using my VIN number the dealer was able to tell I had a 200 amp Bosch alternator. But none of his databases showed a P/N for the regulator belonging to the 200 amp alternator. Interestingly enough it did show a P/N for a regulator belonging to the 90 amp Sprinter Bosch alternator. So I asked what one would do in need of a 200 amp regulator at this dealership. He said weíd just replace the whole alternator. So I gave him Dave Spainís regulator number which he said was superseded by another number and that he had 2 of them in stock. He showed me one. It was twice the size of the smaller rated regulator that I took in to compare. And it matched the picture I had on my phone of the correct one that an internet source had sent me.

Truly this is the short version of how I eventually got to the right number. Part of the confusion involved the many and various sources of part numbers that are used. MOPAR, Mercedes, Bosch and others.

Here are the relevant P/Nís:

5117587AA Ė Our 200 amp Bosch Alternator (a MOPAR or Chrysler or Dodge) (It turns out that most sources on the internet have a way of finding your voltage regulator easier using the alternator number.

5183842AA Ė Dave Spainís Voltage Regulator installed by his dealer (cost for part was ~$99)

68078956AA Ė The new MOPAR number that supersedes Daveís part number above for the correct Voltage Regulator (my Sprinter dealer had this part of $118.

A 003 154 90 06 Ė The Mercedes P/N which crosses to the number MOPAR above

68078956AA - The number printed on the correct Bosch regulator (confirmed by my dealer) are BR14-M3 and F 00M 145 248 (this later number seems to be the Bosch number and those are zeros.)

5133774AA the INCORRECT 90 amp PART which youíll come across if you try to search without being forewarned. The Bosch # for this INCORRECT PART is 1197311213 DO NOT ORDER THIS!

Sources:

Here is where I bought mine on eBay (mostly because I was able to communicate with a person that confirmed that his was the right part for our Bosch 200 amp alternator. Although he lists it for $109 with shipping of ~$15, I made an offer of $85 including shipping which was agreed. http://www.ebay.com/itm/12V-90-200-ALTERNATOR-REGULATOR-BOSCH-MERCEDES-SPRINTER-/140339415168

Hereís one for $76.54 plus shipping at Factor Mopar Parts using the MOPAR number that superseded Dave Sís number. http://www.factorymoparparts.com/68078956aa.html

Hereís one for $64 plus shipping from Sprinter Parts dot com using the Mercedes equivalent number of A 003 154 90 06 but my email questions kept bouncing back so itís unconfirmed as to currency http://www.sprinterparts.com/item.wws?sku=003-154-90-06&itempk=105288&mfr=GENUINE&weight=7.50000
A
merican Engine Co, Ben Daniels (920-543-6646 ben@americanenginesco.com ) helped me a lot. It took a lot of emails but he eventually helped once he had the alternator number. He provided the picture I used that matched the one my sprinter dealer had in stock. Heís says it will be $80 once he gets it and it appears on his site http://www.americanenginesco.com/servlet/StoreFront

You can see a picture of it here http://www.iat-usa.com/parts.html by clicking on Partís Catalog then clicking on search then entering the IAT number of 09134. You see a lot of replacement numbers as well as the correct application. Then click on view picture. This is a picture of one side of it that matched what I saw at my Sprinter dealer. Youíll notice that the Bosch number of F 00M 145 248 is in the data and in the picture.

If you want to see a pic of the other side of it go here: http://www.regitar.com/FlyerPDF/REGITAR%20Rebuilder%202%20of%202011%20w-o%20prices.pdf then search in the document for VRB264. Notice the Bosch F 00M 145 248 number is referenced. Itís the number printed on one side of the correct regulator.

Another pic here: http://www.electricmotorsvc.com/pdf/87-322-09_Transpo_Supl.pdf then search in the document for IB248 or go to page 6. Again notice the Bosch F 00M 145 248 number is referenced. Itís the number printed on one side of the correct regulator.

AND finally here is an example of an ebay listing for the correct regulator but this is NOT OEM so theyíre very cheap. http://www.ebay.com/itm/ALTERNATOR-VOLTAGE-REGULATOR-/160569271210
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Old 02-07-2012, 05:40 PM   #5
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Default Re: Alternator Rebuild

Any idea where to get replacement bearings? 90 Amp alternator(in my case).
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Old 03-02-2012, 01:11 PM   #6
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Default Re: Alternator Rebuild

A 003 154 90 06 Ė Mercedes-Benz P/N

I just ordered a Bosch voltage regulator from my local Freightliner Dealer for my 2002's stock 90amp alternator.
I was told this is the same regulator for all Bosch alternators from 90-200amp which counters some of the information to some posts in this thread.

Luckily I had the Benz part number, as they oddly no longer had any cross reference from Dodge, so all future part numbers now used at the dealer will have to be M-B numbers.

003-154-28-06 Regulator
List price $93.60 (30% discount for my company's "cash" account at the dealer)

Final price $65.10 + tax
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Old 03-02-2012, 01:22 PM   #7
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Default Re: Alternator Rebuild

As HK indicated, rebuild hardly makes sense given the prices which still seem to holding at Amazon. Add to that, it's an upgrade from the typical 90 amp standard. FWIW. vic

Great price on a new Bosch 150 amp alternator
http://sprinter-source.com/forum/sho...amp+alternator

Here's what I did to change mine. At the least the tool list may be of value. vic

Alternator Turbo Resonator Change OM647


http://sprinter-source.com/forum/showthread.php?t=18432
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Old 03-02-2012, 01:30 PM   #8
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Default Re: Alternator Rebuild

Quote:
Originally Posted by Aqua Puttana View Post
As HK indicated, rebuild hardly makes sense given the prices which still seem to holding at Amazon. And it's an upgrade from the typical 90 amp standard. FWIW. vic

Great price on a new Bosch 150 amp alternator
http://sprinter-source.com/forum/sho...amp+alternator

Very true and I would normally agree,except the 90amp has been working fine for my application, the clutch and bearings are OK, and the regulator/brush assembly that I bought is only about 30% of what the replacement alternator would cost.

...also if I was not also as cash strapped as I currently am the extra $110 would not mean as much
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Old 03-02-2012, 01:41 PM   #9
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Default Re: Alternator Rebuild

Quote:
Originally Posted by LuckyDawgz Jim View Post
....
...also if I was not also as cash strapped as I currently am.
I hear ya'. Been there in and out myself so I completely understand.

I have the perfectly good 90 amp which I removed and keep as a spare. It's yours if you should need it. I'll even pay shipping. Just PM me. Good luck. vic
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Old 03-02-2012, 01:58 PM   #10
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Default Re: Alternator Rebuild

Quote:
Originally Posted by Aqua Puttana View Post
I hear ya'. Been there in and out myself so I completely understand.

I have the perfectly good 90 amp which I removed and keep as a spare. It's yours if you should need it. I'll even pay shipping. Just PM me. Good luck. vic
Thank you for the offer Vic...
I still have a job for now, so I will pass on your very generous offer.

It's also my eventual plan to use my old 90amp alt for a spare.
Remember, I was a VW Westfalia guy 1st, so I'm also very big on carrying spares.
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