Alternator Install Problem
 

While reinstalling my altenator into the fan housing I noticed the plastic cap in the back of the alternator is cracked...not a big deal I don't think?

But I also found a little bronze colored bit that fell out...oh crap I thought.
I thought it looked like a electric motor brush that I've seen before on my remote control cars.

Broke out the 101 projects book and found out that you can replace the brushes on the alternator. Once opened up, I confirmed that the little bronze piece was in fact a broken end of a brush.

Guess I'm lucky that I found it before I reinstalled it into the car :shock:

Any idea how much it cost to replace? Is it hard to find? Any leads appreciated.

http://www.dorkiphus.com/porsche/mod...5729.sized.jpg

http://www.dorkiphus.com/porsche/mod...5730.sized.jpg

http://www.dorkiphus.com/porsche/mod...5732.sized.jpg

I’ve never seen brushes for sale at the usual Porsche suppliers but there are several local starter/alternator shops that will probably be able to help. Try the Yellow pages but Alexandria Armature used to have these in stock.

What happened to break the comutator brush??? That and the bearing cover being damaged make me think that it might have been dropped, suffered an incorect reasembly procedure (my bet is the brush was sticking out when the bearing went past and the snapped off stub then punched the cap out) or some other kind of damaging event happened. During reasembly the brushes need to be inspected to see that they are running in the right place on the com rings and that the arm has not shifted in the frame.

When you put in a new set of brushes you can use a toothpick to hold the brushes back in the holder, install the holder then pull out the toothpick to spring load the brushes against the com rings. Push the brushes all the way into the holder and pull the brush wires tight and hold them with the toothpicks to keep the brushes from poping out.

The little black cap keeps the dirt out of the com end bearing and should be in place. If you can't get a new one you can put it back together and seal with thin film of RTV.

If this is a remanufactured unit return it for a new one!

If this was a side of road repair you could stick the stub back in the brush holder and the unit would work fine if the arm was lined up.

I'm not sure really how it happened...Charlie warned me about being very careful when assembing the fan. I just used hand pressure.

Wonder if it happened when we were removing the alternator from the fan housing? Oh well. I'll order a new regulator and cap today.