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MAGA
Join Date: May 2004
Posts: 10,775
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DIY Alternator bearing replacement
Last fall, my '79 SC suddenly started making a horrible screeching noise in the engine compartment. I pulled over and quickly realized it was the alternator. Well it is about spring time and so it is time to fix it. I pulled the alternator out and right away noticed the plastic cap covering the small bearing was laying in loose. Without the plastic cap, the bearing is not supported and the was the primary reason my alternator suddenly went into screech mode. I took the six bolts out of the alternator and seperated it. I then removed the bearings from both ends using an arbor press and a bearing puller. Both bearings are going bad, but the main problem is the broken cap. I can easily find new bearings from MSC or McMaster Carr (Nachi brg numbers: 6303NSL & 6200NSL) , but any ideas on a replacement Marchal plastic bearing cap? I guess I could make one from bronze as I am unclear on what type of plastic can take the heat.
   
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-15-2009, 06:07 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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Bump for the morning crowd.... Anyone know if these Marchal bearing end caps are readily available?
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-16-2009, 05:30 AM
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Registered
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No idea ... but is that a nasty crack in your alternator support, or is it an optical delusion?
I have never had one apart, but the cap in your picture looks like it's a friction fit of sorts, and all loaded in compression. I wonder if a bit of superglue or permatex or whatnot would keep it stuck in place? It's a compression loaded spacer / dustcap from the looks. A washer glued to the flat could keep the parts aligned. Alas, you're a much better tinkerer than I am, so I'll pipe down and see what you come up with!
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'88 Coupe Lagoon Green "D'ouh!" "Marge - it takes two to lie. One to lie, and one to listen" "We must not allow a Mineshaft Gap!" |
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03-16-2009, 01:30 PM
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Registered
Join Date: Oct 2005
Location: Martinez, CA
Posts: 356
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Whats this? doesn't look good.....
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1997 Boxster SOLD 1999 R1100S SOLD 1988 Carrera 3.2 |
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03-16-2009, 03:54 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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Quote:
It is a crack that has been there since I bought the car several years ago. It is only on the back side. My guess is that one of the PO's cracked it while working on it many moons ago. The crack is stable and does not go all the way thru. Seems I have stumped the group here..... I guess that means I need to make one from scratch. Be back shortly with the results.
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-16-2009, 04:18 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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OK, chucked up on a piece of nylatron plastic and after taking some measurements from the alternator housing and the bearing, I turned and bored out my new cap/bushing. I had to cut some relief slots in it to get it to "snap" into position. The bearing feels like it will end up being a nice light press fit into the cap when I re-assemble. I guess I got lucky and only had to make one.
 Now I just need to order the new bearings from MSC tomorrow ($5.86 for the 6200 and $10.08 for the 6303). Of course I will probably paint the fan and housing as my polish job from 2 years ago went to crap. Here are some pics. (forgive me for my mess)      
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. Last edited by Tim Hancock; 03-16-2009 at 05:34 PM.. |
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03-16-2009, 05:06 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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$20.00 for the bearings with shipping and tax from MSC..... Not too bad of a job, glad I did not order a new alternator like I was thinking of doing last fall when it took a crap.
 
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-17-2009, 09:16 AM
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Somatic Negative Optimist
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Very good.
The collector still looks reasonable, maybe just a light polish? As for the crack, I used a small router bit in a Pencil Grinder to make a clean groove and then used JB Weld, worked very well.
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1980 Carrerarized SC with SS 3.2, LSD & Extras. SOLD! 1995 seafoam-green 993 C2, LSD, Sport seats.  Abstract Darwin Ipso Facto: "Life is evolutionary random and has no meaning as evidenced by 7 Billion paranoid talking monkeys with super-inflated egos and matching vanity worshipping illusionary Gods and Saviors ". 
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03-17-2009, 12:07 PM
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Slumlord
Join Date: May 2001
Location: Canada
Posts: 4,983
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Is it worth the trouble and cost to replace the voltage regulator now?
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84 Cab - sold! 89 Cab - not quite done 90C4 - winter beater |
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03-17-2009, 12:44 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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Quote:
It is external on my '79 SC. I did however check the brushes that are on the end of the alternator and they still have some life left, so I am probably just going to throw it back together with the new bearings.
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. Last edited by Tim Hancock; 03-17-2009 at 04:15 PM.. |
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03-17-2009, 01:22 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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All cleaned up and ready for the new bearings to arrive tomorrow. To heck with repolishing my fan. This go around I simply blasted the fan and housing with soda, then etched, then painted with Dupli-color rattle can silver "high performance" wheel paint and Dupli-color semi gloss black 500 deg spray paint. It should hold up, but if not, I can always strip and try something better someday.
I had polished my fan when I rebuilt the engine several years ago, but it is just too much hassle repolishing as I use the car as a daily driver in the summer months.    Getting anxious to get her out for spring! 
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. Last edited by Tim Hancock; 03-17-2009 at 04:11 PM.. |
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03-17-2009, 04:09 PM
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Registered
Join Date: Oct 2000
Location: Centennial, CO, USA
Posts: 1,405
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Hey Tim could you make another bearing cap for me. My alternator died a couple weeks ago, took it to a shop and they told me I needed a new end cap and they could not locate one for me. The bearings they got easily. So I need to buy a new alternator at $169 instead.
Please?
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Bill '72 911T-2.4S MFI Vintage Racer(heart out), '80 911SC Weissach,'95.5 S6 Avant Wunderwagen & 2005 997 C2S new ride. |
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03-17-2009, 06:20 PM
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MAGA
Join Date: May 2004
Posts: 10,775
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Quote:
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-18-2009, 03:12 AM
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MAGA
Join Date: May 2004
Posts: 10,775
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Quote:
The new bearings feel so nice and smooth compared to the old ones! Pressed the big bearing into the fan side of housing, bolted on the retaining plate, slid the chamfer washer onto the shaft, then pressed the shaft into the housing.  Pressed small bearing onto other end of shaft then test fit in front housing. After this pic, I removed this front housing, snapped in my newly made plastic cap, then reassembled the two housings. I had to push fairly hard to close them up all the way due to the nice snug fit of the bearing entering the new plastic centering cap...perfect.  All done... tonight it gets bolted back in the fan housing. 
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. Last edited by Tim Hancock; 03-19-2009 at 11:19 AM.. |
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03-19-2009, 11:15 AM
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MAGA
Join Date: May 2004
Posts: 10,775
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All fixed..... Alternator works perfectly and while I liked the way my fan and shroud looked several years ago "polished", it was looking pretty ratty now. I kind of like my new "cop out" paint job and it should be much easier to keep looking a little better.
Last week (looking pretty lousy)  Now (not too shabby) 
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German autos: '79 911 SC, '87 951, '03 330i, '08 Cayenne, '13 Cayenne 0% Liberal Men do not quit playing because they get old.... They get old because they quit playing. |
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03-19-2009, 04:38 PM
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Registered
Join Date: Jun 2003
Location: Maine
Posts: 1,074
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Hey Tim ..pmed you
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89 Mercedes 300E 77 911s TARGA 79 3.2 widebody 79 911 SC TARGA 97 BMW Z3 |
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04-18-2009, 09:47 AM
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Registered
Join Date: May 2004
Location: Las Vegas, NV
Posts: 66
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I'm rebuilding my alternator now and would like to use a new end cap. Has anyone been successful sourcing these or do I have to fab one ? Seems strange they are so hard to find...
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'83 911SC, '99 986, '15 991.1 GT3 |
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12-25-2009, 05:12 PM
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Registered
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Alright, so I dropped my alternator off at a shop to get it rebuilt; they just called me and said the bearing retainer is cracked, and they can't find a replacement anywhere.
They can get me a new alternator for around $180, but that would need to be gone through as well. So. What do?
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IG@ADDvanced Youtube@ADDvanced www.gruvdesign.com |
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07-10-2020, 09:48 AM
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Under the radar
Join Date: May 2007
Location: Fortuna, CA. On the Lost Coast near the Emerald Triangle
Posts: 7,129
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I would machine one out of aluminum or brass, myself. I can't imagine the original is plastic.
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Gordon ___________________________________ '71 911 Coupe 3,0L outlawed #56 PCA Redwood Region, GGR, NASA, Speed SF Trackrash's Garage :: My Garage |
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07-10-2020, 11:07 AM
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Under the radar
Join Date: May 2007
Location: Fortuna, CA. On the Lost Coast near the Emerald Triangle
Posts: 7,129
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According to these guys they have the "tollerance ring"
https://www.aspwholesale.com/alternators/paris-rhone/automotive/alternator.html https://www.aspwholesale.com/tolerance-ring-va-p2117.html
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Gordon ___________________________________ '71 911 Coupe 3,0L outlawed #56 PCA Redwood Region, GGR, NASA, Speed SF Trackrash's Garage :: My Garage |
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07-10-2020, 11:12 AM
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1988 Porsche 911 3.2
ME 262 (SOLD)
Colibri
Gas Mizer
Mileage King
Dog Bus
My Garage
1971 Porsche 911
Baja Bug
