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Certainly sounds like the alternator, but...
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Posted by Steve Schwedland [Email] (#2368) [Profile/Gallery] (more from Steve Schwedland) on Mon, 15 Nov 2004 10:49:31 Share Post by Email
In Reply to: Re: 1991 Saab 900s Convert - Need to replace an alternator, Kevin, Mon, 15 Nov 2004 09:21:19
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The LAST thing you should do is actually replace the alternator. Before you do that you should check a few less expensive things. The only time you should need to replace the alternator is when the bearings inside it have gone bad.

First check all the wires that are connected to the alternator are still good, sometimes they look OK at first but after closer inspection they are bad. It is very common for the big wire between the alternator and the starter to fail, it gets corroded and falls apart. One time I was having trouble, I jiggled that wire to see where it went and it came off in my hand.

Next, pull the voltage regulator out and check the brushes. If the brushes are worn down to 3-4mm, then it is bad and needs to be replaced. VR's cost less than $50.

The vast majority of all charging problems are caused by one of these two problems. From what you describe, it sounds to me like a ground wire problem which is pretty common. VR problems generally happen over time.

Once you do get the system charging again, you may want to look at replacing your battery. When the battery is completely discharged and then recharged several times it tends to go bad.

Best of luck.

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