[dkirk]

At 144,000 miles on my ’88 Carrera, the original alternator bearings are occasionally making noise, as confirmed via stethoscope with engine idling. Removing the belt and spinning the fan by hand, a slight “tinkling” noise can be heard and the fan/shaft spins and coasts quite freely, indicative of dry bearings. There is no axial nor radial play in the shaft – a good sign. Belt tension is always adjusted correctly and is not too tight and proper torque is applied to the retaining nut. I’m not sure what brand of alternator my engine is equipped with, but it either has to be the Bosch or the French-made equivalent.

I feel I can finish up this year’s driving season without problems but I’d like to rebuild the alternator this winter when the car is out of service. Would like to do this job myself but searching the “How To” articles and forum postings, I’m unable to find anything – seems most folks just take their alternator to a specialty shop. It would seem that a general refurbishment would consist of replacing both bearings, new brushes, polishing the slip rings and a thorough internal cleaning. Obtaining new sealed ball bearings would not be a problem but I’ve not seen brushes offered by our host, or any other supplier for that matter. So, for any of those that have rebuilt their own alternators, my questions are as follows:

1) Where can brushes be obtained for these alternators?
2) Are there any unforeseen “surprises” that might be encountered, requiring
special tools, etc.?

Thanks guys – appreciate any advice and suggestions.