Alternator blues...

The saga continues...

I've checked and rechecked the wiring and about all I could suspect was one battery terminal didn't seem to be tightening up properly, so I replaced it. I didn't get to the ground on the block since it is such a PITA to access. But when I eventually put in the new alternator, I will likely add an additional ground and recheck things again.

I dropped off a dead alternator to the local repair shop and had an interesting discussion with the owner. He has quite a reputation around here and comes highly recommended. After telling him my tale, he was intrigued to say the least. He immediately spotted the smaller pulley and did not believe that was a good thing at all. He didn't think over-revving would kill the diodes or regulator and suspected if it was indeed over-revving, the rotor and/or stator would be bad. Being a 'small-frame' alternator, he seemed to be leaning to that supposition. Only an autopsy would tell the tale.

He seemed confident he could come up with a solution but he would need to do some testing. We talked about higher amperage capacity but he down-played it as a solution to charging at idle. Hopefully he'll call in a few days with some good news.
 
JP...I didn't read this entire thread but I can tell you this....my small pulley on my alternator killed every single one. I would pin the throttle and at max RPM's at shifting from 1st to 2nd I would lose the regulator (seen on guage). I went through 9 alternators in 4 months before I put two and two together. Put the stock pulley back on and never had a problem. Lucky for me I was able to warranty each alternator through my shop.

Trust me on this...do NOT pulley your alternator because it fries the regulator and kills diodes at the same time. You just have to sacrifise low/no charge rate at idle.
 
NINE???? alternators???? WOW....your learning curve runs way to the outside.....LOL

(I sure am glad there are SOME people here I kin mess with)
 
Well to add to this...

I purchased a "new" autolite aka motorcraft (stamped on the bottom) alternator for the crown vic from the local parts store on 7/10/07 It started throwing a charging light as of the last 6 months... I checked the voltage and it was all over the place... 15.4V etc.

Long story short, I had to do a change in the back of the parts store parking lot...

Original lasted nearly 10 years and 150 k miles... replacement lasted 2 years 9 months and 80k miles..

#3 New Hencho in Mehico alternator in right now.
 
That reminds me....when mine would fail, I could see it instantly on my battery gauge on the pillar pod. Sometimes it would just drop to battery voltage (12.4) and twice it pegged the gauge at 16+ volts!!!
 
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BadSax said:
Ok, I'm keeping my fingers crossed that you get a diagnosis... :D

:D -J

The autopsy has been completed and the official cause of death is that the rotor windings suffered catastrophic failure and took out the stator. There was an open circuit on the inverter. Rectifier is likely OK but was not tested.

It was confirmed - death by over-revving.
 
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The autopsy has been completed and the official cause of death is that the rotor windings suffered catastrophic failure and took out the stator. There was an open circuit on the inverter. Rectifier is likely OK but was not tested.

It was confirmed - death by over-revving.

I'm glad you summarized the finding in laymens terms :D
cause I have no idea what the stator or rectifier are... :D
although I think rectifier is a fun word, and more parts should be called "the rectifier"... :D

So now what?

anim_49.gif
-J
 
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I'm gonna find an OEM Cobra unit?
 
Ok, I understand a stator, rotor, and rectifier ( Joe, a rectifier rectifies AC current into DC current :D)
but what the heck is an inverter doing in there (an inverter changes DC into AC)?:confused:
 
but what the heck is an inverter doing in there (an inverter changes DC into AC)?:confused:

I was only quoting the coroner. ;)

He was rattling off stuff pretty quick and my shorthand is not what it once was. But he did say "inverter" - I don't know what else he could have been referring to except possibly the regulator?
 
Ok, I understand a stator, rotor, and rectifier ( Joe, a rectifier rectifies AC current into DC current :D)
but what the heck is an inverter doing in there (an inverter changes DC into AC)?:confused:

Some vehicle components may run on AC...but that's just a guess.
 
Ordered a new GLV-8356 from RockAuto.com while other options are being explored. :)
 
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That is NOT a viable option. If it can't handle 7000 rpms now, what's going to happen later when it goes to 8000 rpms?
 
New mustang revs to 7k. You may want to find out more details about how that set-up works. Would it make sense to get a bigger pulley to reduce the strain on the alternator?
 
Would it make sense to get a bigger pulley to reduce the strain on the alternator?

That's basically what I'm doing now - problem is it does not charge at idle.

I will try a Cobra alternator with the biggest pulley that will charge at idle.
 
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