Rebuild your own alternator

[Tercel GTS]

Ok, as some of you may know, I build alternators and starters for a living. I took a series of pictures of a Paseo alternator that came through my shop not long ago, figured I'd post the info here.


First you have the unaltered alternator, remove the 3 nuts, maybe one bolt, ground plate and battery insulator.


Should look like this now..


You'll see the two tiny srews holding in the brush holder, make sure the screwdriver fits properly or it will strip them out!!!



Simply replace the whole assembly then put it back together. This fixes 98% of alternator issues.

[Rycam]

More than awesome info!!!! Thanks!

I do have a question: Is there a particular spray cleaner that is used to clean the outer windings before they are repainted?

[88camry]

what manufacture makes the rebuilt kit?

I have found kits at Canadian tires, but have not seen one that camry, there all domestics.

[Tercel GTS]

Rycam
I clean the windings with a glass bead blaster before repainting, gets off all the loose stuff and makes a good foundation for the paint.

88camry
There is no kit. I order individual parts for whatever I need, this is what I do for a living. We have most anything in stock, what parts do you need?

[Stealth]

it is possible to rewind your own alternator or is it something to leave to the professionals? also is there anyway to just swap out parts so that it creates more amps or again is that something to be left the professionals? and last of all would you be able to build a higher powered alternator for any of us?

[Phi]

added to sticky

[Tercel GTS]

Originally posted by Stealth
it is possible to rewind your own alternator or is it something to leave to the professionals?

The parts you can get to under the cover on rear are easy to replace and anybody that can feel when to STOP tightening a screw can do this with no problem. Beyond that it's best to leave to a pro unless you have a few spares to practice on.

also is there anyway to just swap out parts so that it creates more amps or again is that something to be left the professionals?

The japanese have put as much windings in the housings as will fit. The only way to get higher power from a specific size alternator(nippon denso that is) is to increase the voltage regulator's capacity. I use a # F-540HD that I get from a company in Florida called TRANSPO or if I need even more power I'll get a POWERLINE . Beyond that you use a later year alternator from the same model car.

and last of all would you be able to build a higher powered alternator for any of us?

If you need one, sure. On 4banger camry's I can sell up to a 250amp Delco that bolts right on with only a few minor mods(adjusting bracket and wire harness), or large frame
NipponDenso
alternators with regulator either modified to fit your wiring plug, or supplied with a plug and simple directions to swap ends. Later model cars sometimes have different plug types.

[Stealth]

How much would it cost me for a 250 amp? I'm going to be doing competitions in maybe half a year, or less hopefully, and will definately need something much more powerful. Also my friend with a 93 V6 is going to need something, maybe not quite as powerful though.

[Tercel GTS]

Are you going to need me to prefab an adjusting bracket or will you be covering that part yourself?

[luisitol]

so how much would it be for say a 150 amp and a 250amp alternator including the adjsuting bracket?

[Stealth]

Eh a bit late here, since I lost track of the topic. But I would need you to prefab it since I'm not so great at making things, especially out of metal.

[Tercel GTS]

The 250 with the standard adjustable regulator and the wire harness that connects them to each other goes for $600. If anybody is really interested in one I'll find out what the bracket mods would cost and let you know. To build a 120 amp alternator would be far cheaper for me and you as long as that's all the car needs. I can build the 120's for $250. These should fit with only minor mods and plug up to your existing regulator connector. As always when increasing the power make sure you increase the wire size to handle it and keep it fused.

[92CAMRYGTS]

what is the stock amp for a 92 5sfe?

[Tercel GTS]

ALTERNATOR 4 2.2 132 5SFE 12th VIN Digit = 0 1-1964-01ND ND IR/IF 70

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ALTERNATOR 4 2.2 132 5SFE 12th VIN Digit = U 1-1857-01ND ND IR/IF 80

[RedAE102]

I recently bought a remanufactured alternator off eBay, which promptly quit charging only a week later (no returns of course). I drive a '93 Corolla, which was built in Japan and came with the 70-amp Denso unit. My factory alternator still charges fine, but the only problem is that the bearings are on their way out. I do know the problem with the alternator I bought is in the alternator itself, as its regulator and rectifier work just fine on my factory unit. Since I have this extra alternator sitting here and gathering dust, I already replaced the worn brushes from the factory alternator with the ones from the reman one.

So my questions are:
Is it imperative that the other parts are changed, or do you think they will be fine for a few more years?
Could you elaborate more on the pulley nut removal? What kind of air tools are necessary to remove it?

Thank you very much in advance! This is a great gesture for the board!