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Old Mar 10th, 2020, 13:44   #15
Laird Scooby
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Join Date: May 2012
Location: Lakenheath
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If you have an electronics lab at your disposal, first thing to point out is that although you can get a basic test on the rectifier with a multimeter, you need to load them up to test them. A 21W bulb is usually sufficient and then reverse the polarity to get the go/no-go operation of all 6 rectifier diodes. Also check the diode "trio"that feeds from the outputs of the stator to the voltage regulator. For the voltage reg, you will need a dedicated voltage regulator tester - not cheap and unless your electronics lab is an autoelectronics lab, highly unlikely you'll have one floating around!

You'll also need a 100+W soldering iron to desolder the rectifier from the stator windings and also the slip rings from the rotor windings. You also need to measure the distance from the nearest slip ring conductor to the back of the rotor as they vary and when the new one is fitted, you'll need epoxy resin adhesive to secure it in place.
There are also 2 different diameters of slip ring applicable to Bosch alternators of this age, 28mm and 32 mm, the voltage regulator is different on both as well not ot mention slight other differences but generally there are two main voltage regs fitted to the Bosch alternators from this time.
The brushes come with the voltage reg, it's not worth trying to renew just brushes as the regs tend to fail soon after the brushes have worn out.

Then you'll need bearing pullers and a press of some description to remove and refit the bearings and slip rings. Also take photos as you strip it down, there are some spacers and washers, particularly on the Drive End that need to be kept in order for the pulley to run in the right place. From memory, you need an 8mm Allen key and 22mm cranked ring spanner to unbolt the pulley.

That should get you started, i could never remember the bearing numbers on the Boschbut 6302ZZ rings a bell somehow.
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Dave

Next Door to Top-Gun with a Honda CR-V & S Type Jag Volvo gone but not forgotten........
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