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Replacing the brushes - long answer.
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Posted by Gene N [Email] (#1094) [Profile/Gallery] (more from Gene N) on Tue, 12 Nov 2002 17:00:00 Share Post by Email
In Reply to: Replacing brushes in Bocsh Voltage regulator: Where, Daren, Tue, 12 Nov 2002 16:06:55
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You can find the brushes on any site that has the standard parts catalog software. Two sponsors that use it are Trollhatten (http://www.cybertroll.com) and Andrews (http://www.andrewsofprinceton.com). Non-sponsors that use the catalog are http://www.thepartsbin.com and http://www.megaparts.com. The brushes are in the $3 range, and come in pairs.

I've done the brushes in two alternators, and it is not quite as easy as just unsoldering them. The brush wires are soldered and crimped. So, first you have to unsolder using a "solder sucker" or wick to remove as much as possible. Then, using an awl or solder pick, along with some long nose pliers, you have to open up the hole and release the wire. Next you will have to search the floor for the spring that zinging across the room, because you have to reuse it with new brush. Widen out the hole as much as you can because you have to fish the wire connected to the new brush through the hole, and the wire is stranded (think wet noodle). Once the wire is through (tin the end if you are having trouble), grab it and pull the brush against the spring until the brush is in the holder, but still sticking out quite a bit. Crimp the end to hold the wire and resolder it.

The first one took about 3/4 of an hour of futzing. The second one was about 15 minutes.

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