How to put the brushes in the alternator

Hi Charles
I haven't seen an Alternator with a Fuse.
They Generate 35-55 or more Amps and are usually connected directly to the Battery Positive. Check at Alt. Main Terminal with MultiMeter. Check for Good Ground.


The small wire on the back of the alternator often comes from Ignition Key + to control the charge rate.
The Modern Alt. also has an internal Regulator Circuit to control charge rate.

If trying to save money.... Alternators can be split open on the Bench and repaired. Just put a mark across joint before opening.
Use a brush hook (make one) to hold brushes back while re assembling.

Items to watch for:
Brushes Worn Out - no juice to Rotor to excite (generate)
Diodes Blown - (Multimeter Test on Diode Function for shorts / open. Simple Unsolder, Press out & replace
Regulator Blown - Buy replacement
Stator Coils Corroded or Shorted/Open or bad solder joints.

Remove Alternator & Bench Test.

Good Luck
Alternator automotive

How to diagnose and repair bad alternator in your car or truck

When brushing the brushes with oil, they are damaged
The minimum voltage is 12.5

Alternator has to be on the work bench & come apart

I can assure you that isn't necessary

The commutator would be worn out first &
most likely other parts, before any brushes,
if they are even avail anymore

My mazda121 i put nee brush but when i play music it burns brush i dnt know what causes that help please

Your alternator-mounted voltage regulator has failed. Luckily, your voltage regulator is
replaceable separately from the alternator (most voltage regulators are integral to the alternator,
and cannot be separately serviced).

Note: this works for 3.8L cobra alternators/voltage regulators only - in the 4.6L model, the
voltage regulator is an integral component of the alternator.

1999 Ford Mustang Cobra -3.8L engine

3.8L Engines

1. Disconnect the negative battery cable.

2. Remove 4 Torx® head screws holding the voltage regulator to the alternator rear housing. Remove the regulator, with the brush and terminal holder attached.

Fig. 1. The regulator and brush/terminal holder are mounted on the backside of the alternator




Fig. 2. The regulator and brush/terminal holder are secured by 4 Torx® head machine screws




Fig. 3. Hold the regulator while removing the screws to prevent the regulator from dropping out and damaging the brushes





3. Hold the regulator in one hand and pry off the cap covering the A terminal screw head with a small prybar.

4. Remove 2 Torx® head screws retaining the regulator to the brush holder. Separate the regulator from the brush holder.



Fig. 4. Slide the regulator out-the brushes will move out of the holder




Fig. 5. The brush and terminal holder can be separated from the regulator once it is removed from the alternator




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To install:

1. Install the brush holder on the regulator with 2 retaining screws. Tighten the screws to 25-35 inch lbs. (2.8-4.0 Nm).

2. Install the cap on the head of the A terminal screw.

3. Depress the brushes into the holder and hold the brushes in position by inserting a standard size paper clip, or equivalent tool, through both the location hole in the regulator and through the holes in the brushes.

Fig. 6. When installing the regulator, press the brushes back into the housing




Fig. 7. Use a thin piece of soft material, like this plastic wire tie, to hold the brushes in position while replacing the regulator, or use a paper clip inserted in the hole





4. Install the regulator/brush holder assembly and remove the paper clip. Install the attaching screws and tighten to 20-30 inch lbs. (2.3-3.4 Nm).

5. Connect the negative battery cable.

Hi, the regulator is integral to the alternator on your Jag.

Part Number: 14561 Weight: 13.0 lbs Warranty: Limited Lifetime Notes: 75 Amp alternatorPremium reman. Save the pulley, fan, shaftkey and/or fan spacer and mounting hardware from your failed alternator. You will need to install these parts on your replacement alternator. Unit Manufacturer: Lucas Amperage: 75 A Pulley Type: Sold without a pulley Fan: External Regulator: Internal Part Number: 14561 Weight: 13.0 lbs Warranty: Limited Lifetime Notes: 75 Amp alternatorPremium reman. Save the pulley, fan, shaftkey and/or fan spacer and mounting hardware from your failed alternator. You will need to install these parts on your replacement alternator. Unit Manufacturer: Lucas Amperage: 75 A Pulley Type: Sold without a pulley Fan: External Regulator: Internal Part Number: 14561 Weight: 13.0 lbs Warranty: Limited Lifetime Notes: 75 Amp alternatorPremium reman. Save the pulley, fan, shaftkey and/or fan spacer and mounting hardware from your failed alternator. You will need to install these parts on your replacement alternator. Unit Manufacturer: Lucas Amperage: 75 A Pulley Type: Sold without a pulley Fan: External Regulator: Internal

it sounds like the brushes in the alternator are completly worn out. just replace the alternator as other related things you cant replace-slip ring-are probably worn and the individual prts are hard to get.if you wnat to try try finding a seperate brush set on the web, take the alternator apart and see what happens.

renew the alternator ,the brushes/commutator are gone .put it on a better becch test with a 60 amp loading minimum and see what i mean or better still remove the regulator housing and inspect the brushes and the commutator and see what i mean

still sounds like a alternator issue,maybe grounding out at 1 of the brushes,try hitting the alternator with a hammer ,not really hard to break it,and see if it helps,if it does replace the brushes,which are usually about $25.00-$35.00,if it doesnt charge anymore then the brushes are bad.usually alternators go about 200,000 miles with no problems

using a mega on rectifiers can damage them
you should take the alternator to an auto electrician for a proper bench test