Alternator Slip-Ring Worn Out - Fixed With A Thick Wire

[Simple]

I would like to share the way I resolved the problem of worn out alternator slip-rings.

 

I couple of years back I changed the contact brushes on the Valeo Alternator on my C8, I noticed that the slip-rings are badly worn out; I ignored that fact, fit the new brushed and assembled the alternator back. It worked until a couple of weeks ago, when it started failing...

 

I took the alternator out and examined it. The slip-rings were grooved to the plastic, no more cooper. I searched the forums, they were talking about replacement parts. I have ordered and received the replacement slip-ring, but the show stopper was I need to pull a bearing out and did not have a puller.

 

However, I bout 20cm heavy duty electric cable (the one used for wall sockets) that has three cooper strains of about 1mm thick for 0.5 Euro. I wrapped the copper strain tightly in the Slip-Ring groove and using a gas operated soldering iron (after removing the tip to utilize the direct thin flame), I soldered the wrapped cooper wire in position and filed it smooth, then reassembled every thing back.

 

This is much cheaper than an expensive full replacement and has been working well since then.

 

I wonder why the manufacturer did not create this part to be easily replaceable??. Having solved the problem this way, I think it is possible to create a heavier duty cooper ring measuring 1.25mm thick and 5mm wide with the length required to fill the groove (filing may be needed for perfect fit). I might attempt it next time.

 

Simple.

Edited July 22, 2015 by Simple