1998 Windstar Alt Problems

partsman589 · 12-20-2006, 04:45 PM

My van has 238000 kms on it and I have had to replace the regulator in the alternator not once but twice. I believe it is going again. The blower and lights slow down and dim when the engine reaches 2000 RPM and the alt light flickers at about 3000 RPM. I am sick of taking the alt off. Can someone help me understand the problem and possibly give me a solution.
richardrossiter@nf.sympatico.ca

CraigRK · 12-20-2006, 05:13 PM

partsman589

I replaced my alternator and S-belt this past weekend (98 Windstar w/ ~270,000 km) and may have some insight. But could you please clarify: Have you replaced the entire alternator once or twice or just the voltage regulator (with the attached brushes) that is intergral the the alternator?

CraigRK

partsman589 · 12-20-2006, 06:32 PM

replaced the voltage regulator with brushes. The brushes let go in both regulators. Really pi**ing me off.

CraigRK · 12-21-2006, 03:58 AM

When I replaced my alternator, I checked the condition of the brushes after-the-fact. The brushes were indeed worn down, but what made replacing the brushes only not a viable option was that the copper bands on the back end of the alternator shaft were excessively worn and damaged where the brushes make contact. If the copper bands on the shaft at this location are pitted, uneven or damaged in any way (as they would be if the alternator ran for any time with poor or damaged brushes), or if the shaft diameter has been worn to too small a diameter, I would imagine the brushes would fail rather quickly. And damage to the surface of the copper bands that would wear the brushes quickly might not be glaringly obvious.

If this is your problem, the solution is simple, but a few more $$$. (And ya gotta pull that damn unit off again!) Replace the entire unit with a new or remanufactured alternator that has had the copper band turned smooth.
Best of Luck.

CraigRK