alternator rebuild

[cdonahue]

just blew the alternator, (bearings went), was wondering if anyone has ever rebuilt their own, or had theirs rebuilt. what did it end up costing you?
thanks
chris

[paul somlo]

Wondering how this ended? I've learned the hard way, that the Valeo alternator on the M44 is not easily rebuilt, owing to the difficulty in opening up the case.

Paul

[cdonahue]

I ended up buying a used alternator at a junkyard. That alternator also went only a couple months later but luckily I got a warranty with it and they replaced it at no charge. The car has long since been sold, but I will never forget it going through several alternators in one season.
Best of luck with yours!

[bazar01]

Originally Posted by paul somlo

Wondering how this ended? I've learned the hard way, that the Valeo alternator on the M44 is not easily rebuilt, owing to the difficulty in opening up the case.

Paul

Not sure if I have a Bosch or Valeo alternator, but I was able to rebuild my alternator a long time ago. I replaced the bearings, brushes and regulator.
I got the parts from this vendor. New alternators are pricy so rebuilding is the way to go. A used one will be a gamble.
http://www.aspwholesale.com/alternat...uild-kits.html

[paul somlo]

Bazar - you're just the guy I was looking for.

I got my alternator back together last night, having replaced the bearings, wasn't pretty. It turns out the case halves on the Valeo alternator are not easily separated. The stator is mechanically retained in the front case half and soldered into the rectifier, which is, of course, part of the back case half. The kicker is that the retainers are not accessible until the case is split, which means that you can't open the case until you either unsolder or cut the stator wires at the rectifier.

I ended up cutting the stator leads at the rectifier, drilling out the leftover stub from the rectifier terminal, clipping the rectifier terminal lengthwise to open it, and resoldering the stator leads to the terminals using a wrap or two of #18 wire as a "tourniquet", to mechanically tie the terminal and the stator lead together before soldering. The result is not pretty, but it seems pretty stable. I used a 135 watt soldering gun, as the job requires a fair amount of heat. When I started, I didn't realize that the stator was attached to the front case half, and in prying the two halves, must have pulled enough slack out of the stator wires to still reach the terminals after they were cut.

I've attached some pictures of the case, showing the feature that makes disassembly so difficult, a small "button" which bears on the stator edge. The other edge of the stator rests on a ledge machined into the front case half. There are four of these retainers around the perimeter, don't know if this construction is unique to Valeo. My understanding is that, if the alternator's construction is such that there's a space visible between the two case halves with the alternator assembled, rebuilding will be much easier.

Bazar - would you be so kind as to check what type of alternator you have? Or maybe even post a picture showing the joint between the case halves? I'm thinking that the 318ti was produced with two different alternators. I do remember, early on, a recall where the dealer replaced my alternator, maybe two years after I got the car.

By the way, the cheapest replacement I found was on Rockauto.com - a Remy 13312 at $113.79, w/$90 core charge. It appears to be identical in construction to the Valeo.

Paul

[bazar01]

I still have the original engine that overheated sitting in my garage.
It has the Valeo alternator and has the same retainers on the front case half.
The alternator that came with the used 1998 TI engine I bought has the Bosch alternator.

[paul somlo]

Originally Posted by bazar01

The alternator that came with the used 1998 TI engine I bought has the Bosch alternator.

So the one that you rebuilt is the Bosch? If so, wondering if you have the PN on that alternator?

It appears that the Bosch alternator is offered in two different styles, same Bosch PN, one where the bearings are easily replaced, one not so easily, here are links to the pics:
http://www.rockauto.com/info/23/BS_AL0736X_Rig.jpg

https://www.autopartsapi.com/eEuropa...57f07d197b.jpg

Somewhat confusing. I suppose from the standpoint of someone who just wants to replace their alternator and never deal with rebuilding it, it doesn't matter. But I figure I'm at least half way through the slip rings on my Valeo and they're not replaceable. And truthfully, I don't want to have to go through the ordeal of opening the case again. And your statement about used ones being a gamble is very much correct, even applies to rebuilt. I checked two different rebuilder's websites, and they replace bearings and brushes, resurface the old slip rings, and retain the electronics if they check good. I'd like to identify one that fits, is easily rebuildable, and has complete parts availability (brushes, slip rings, bearings, regulator, rectifier).

Paul

[bazar01]

Originally Posted by paul somlo

So the one that you rebuilt is the Bosch? If so, wondering if you have the PN on that alternator?


Somewhat confusing. I suppose from the standpoint of someone who just wants to replace their alternator and never deal with rebuilding it, it doesn't matter. But I figure I'm at least half way through the slip rings on my Valeo and they're not replaceable. And truthfully, I don't want to have to go through the ordeal of opening the case again. And your statement about used ones being a gamble is very much correct, even applies to rebuilt. I checked two different rebuilder's websites, and they replace bearings and brushes, resurface the old slip rings, and retain the electronics if they check good. I'd like to identify one that fits, is easily rebuildable, and has complete parts availability (brushes, slip rings, bearings, regulator, rectifier).

Paul

Why don't you check this site? They have all the parts available. Call them up to verify accuracy of parts.

Valeo alternator parts: http://www.aspwholesale.com/alternator-parts/valeo.html

The Bosch is on my car right now. No time to peek and get the PN.

[paul somlo]

They show parts for both the Bosch and the Valeo, but when I called them, they insist that they don't have parts for cars that weren't made in USA. Only Bosch America.

Online, they show the rectifier and regulator/brush assembly for the Valeo, and brushes and bearings for the Bosch. It's a safe bet that no matter which alternator, bearings will be a commodity and easy to get. I think the sticking point will be slip rings, which do wear, but not very quickly. I'm at 232,000 miles and my slip rings appear to be about half worn.

I did replace my brushes a while back, just the brushes, not the whole assembly. For any interested party, on the Valeo they're 6.4mm x 4.6mm x 14mm. I've got a PN of 38-9402 in my notes, not sure which mfg that pertains to.

I'll have to call Smith Electric here in Greeley and see what they can tell me about Bosch vs. Valeo and parts availability.

Paul

[bazar01]

Yes. Smith Co Electric will be a good source too. I have used them for parts on my Porsche 911 Bosch alternator. I saw some Valeo alternator for Bobcats on their site.
Have your Valeo alternator number ready.

https://smithcoelectric.com/
contactus@smithcoelectric.com or by phone at (970) 353-3121, toll free 888-860-4339.

[paul somlo]

I bought my bearings from Smith, they told me that slip rings for the Valeo were not available. I'll call them and see if I can sort out this business with the Bosch alternator, but I'm suspecting mixed usage on the same model car, and maybe even within the same model year. And parts availability may not be any better for the Bosch, but I'm thinking it may be a whole lot easier to open up the case.

Not sure that I'll need that toll free number for Smith - they're about 2 miles away from me.

Paul

[bazar01]

Originally Posted by paul somlo

Not sure that I'll need that toll free number for Smith - they're about 2 miles away from me.

Paul

You are one lucky guy. I noticed that you are also in Greely, CO.

[paul somlo]

I just spoke to Smith.

There was usage of the Bosch on the 318ti at one point, but now they're sourcing from Valeo, apparently. Smith confirmed availability of all repair parts on the Bosch - brushes, slip rings, regulator, rectifier, bearings. And, as mentioned earlier, the Bosch case can be split without unsoldering wires.

Here's the kicker: The only way to be sure that you're getting the Bosch version, is to actually lay eyes on it. Bosch rebuilds the Valeo alternators, as well as their own, and puts their own label on them (see Rockauto link above), as PN AL0736X. As new, the Bosch was labeled with PN 0123320012. I don't actually know if the Bosch is available new anymore. My guess, is that if you want the easily rebuildable Bosch, you're going to have to find one used and either look at it yourself, or send the seller pictures to confirm.

[BlackBMWs]

great info, thanks guys.

[jaedon5]

I would rather buy a used one. A local shop rebuilt my alternator and it went bad again after 4 months.