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Alternator brushes and voltage regulator - renewal
Engine electrical systems / Alternator brushes and voltage regulator - renewal


Note: This procedure assumes that replacement parts of the correct type have been obtained. At the time of writing, no individual alternator components were available as separate replacement Ford parts.

An auto electrical specialist should be able to supply parts such as brushes.

The following procedure is for the Bosch unit fitted to the project vehicle - details may vary for other alternator types.

1 Remove the alternator from the vehicle (see Section 12) and place it on a clean workbench.

2 Remove the three screws, and withdraw the plastic end cover (see illustration).

13.2 Renewing voltage regulator/brush holder - Bosch alternator. Remove three
13.2 Renewing voltage regulator/brush holder - Bosch alternator. Remove three screws and withdraw end cover . . .

3 Remove the two voltage regulator/brush holder mounting screws.

4 Remove the regulator/brush holder from the end frame (see illustration). If you are renewing the assembly, proceed to paragraph 8, install the new unit, reassemble the alternator, and refit it to the engine (see Section 12). If you are going to check the brushes, proceed to the next paragraph.

13.4 . . . then remove regulator/brush holder assembly (secured by two
13.4 . . . then remove regulator/brush holder assembly (secured by two screws)

5 Measure the exposed length of each brush, and compare it to the minimum length listed in this Chapter’s Specifications. If the length of either brush is less than the specified minimum, renew the assembly.

6 Make sure that each brush moves smoothly in the brush holder.

7 Check that the slip rings - the ring of copper on which each brush bears - are clean. Wipe them with a solvent-moistened cloth; if either appears scored or blackened, take the alternator to a repair specialist for advice.

8 Refit the voltage regulator/brush holder, ensuring that the brushes bear correctly on the slip rings, and that they compress into their holders. Tighten the screws securely.

9 Install the rear cover, and tighten the screws securely.

10 Refit the alternator (see Section 12).


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