So my alternator died on Monday, and in hind sight it was on its way out. I took it apart on Tuesday to see if I could make it work. And discovered the brushes had reached the end of their reach. But unlike a motor where the brushes are finished when the spring touches the holder, and you can sometimes recurve the spring to make them ware longer. These brushes are limited by their lead wire being to short for them to come out of the holder. So I found that by melting the solder, and adding a little more solder you can get the brushes to come out a little farther and thus get more life out of them. I didn't take any pictures of my soldering, I should next time. But here's a picture of the brushes so you know what I'm talking about.
After I had spent almost an hour doing this, I reinstalled the alternator, and found out it hadn't made any difference. I hooked up my volt meter to the car and ran it with the lights on for 5mins and only lost 0.02V but it was running at battery voltage 12.6v so the alternator was doing something. I think the rectifier went. The car was running with the battery light on when I bought it and the previous owner equated it to the battery being to large for the car. Being a heavy equipment technician, I knew that was highly unlikely. But since it was fine for 1000km and never showed any signs of discharge I didn't look into it. Once again in hind sight I should have
I bet it would have shown me the alternator wasn't putting out enough voltage.
Good news! I was able to get a refurbished alternator today as planned. I also got a new PCV and new Spark Plugs
installed them all this evening so tomorrow will be even better mileage! I also had to patch the vacuum line to the PCV I got a T and hoses to try and recreate the factory one. But it wouldn't fit.
Well here's looking forward to tomorrow. My economy numbers will be a little screwy when I fill up on Friday cause I drove about 200km without an alternator. Not only that but I push started it several times trying to make my was home, before my friend came and brought me a charged battery to drive home with. I did as much EOC as possible and drove at 30km/h for about 10km because the car would keep going at that speed if I feathered the throttle. Its interesting to see how little electricity it needs to simply run the engine.
I haven't installed an alternator shut off switch yet, I have to do some research to see how to properly cancel it with this alternator. I can't install a switch on the brush like the instuctable says. I might be able to put some rubber washers and eyelets on where the brush mounts and interrupt it that way, hmm...