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Updated alternator refurbishment post (with pics) #1619012
16/04/2018 10:40
16/04/2018 10:40
Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
DaveG Offline OP
Club Member 311
DaveG  Offline OP
Club Member 311
Forum is my life

Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
I've updated this post to include pics hosted on so-called TinyPic instead of Photo****It. Please can someone overwrite the existing post (with broken photo links)?

click to enlarge
Here's the original fitment alternator, Fiat part number 46404424 but with a Magnetti Marelli sticker showing model number 63321426 (and type A127IR-100A)

click to enlarge
First remove the 3 thin 10mm nuts and remove the black plastic rear cover

click to enlarge
The regulator is the black plastic assembly at the bottom, the rectifier is the fancy metallic assembly at the top/sides

click to enlarge
Remove the 3 small bolts/screws holding the regulator in place (from L-R medium, long and short, use a suitable screwdriver apart fromt the long one where a 6mm socket works best) as well as the nuts/washers/collar on the main alternator output terminal, and the 8mm nut on the right side

click to enlarge
Close-up of the regulator with bolts/screws removed

click to enlarge
Remove the regulator, exposing the slip ring

click to enlarge click to enlarge
The brushes are clearly visible from below

click to enlarge click to enlarge
Carefully slide the brush cover away from the regulator assembly to reveal the brushes

click to enlarge click to enlarge
The rectangular brush covers at the edge can be unclipped and removed to reveal the wiring connectors to each brush

click to enlarge
Spare parts are available from Wood Auto Supplies where the regulator (aftermarket or Magnetti Marelli), rectifier and slip ring is available, but not the brushes, although they can be found by searching on alternative alternator model numbers, eg: Lucas.

Re-assembly is the reverse of removal, except that the brush cover needs to be clipped on after the brushes are eased over the slip ring.

click to enlarge
Push in the first brush as you slide the regulator over the main output post and smaller post on the other side

click to enlarge
Push in the second brush as you ease the regulator assembly further down

click to enlarge
Push down to seat the regulator, making sure the brushes line up with the slip rings

click to enlarge click to enlarge
Clip the brush cover back on and push home with a "click"

Then replace the medium/long/short bolts/screws, the nuts etc. on the main output terminal, and finally replace the rear cover and 3 nuts.


1996 Portofino 20vt & 2000 Pearl White Plus
1985½ & 2016 2017 Fiat 124 Spider + XF Sportbrake
Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619013
16/04/2018 10:42
16/04/2018 10:42
Joined: May 2012
Posts: 1,912
Going North on the A9
dante giacosa Offline
My life on the forum
dante giacosa  Offline
My life on the forum

Joined: May 2012
Posts: 1,912
Going North on the A9
Well, this couldn't have come at a better time for me!

Thanks DaveG!!

P.S.- the photography in this, is exceptional

Last edited by dante giacosa; 16/04/2018 10:48.
Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619017
16/04/2018 10:48
16/04/2018 10:48
Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
DaveG Offline OP
Club Member 311
DaveG  Offline OP
Club Member 311
Forum is my life

Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
Yes, it was done for you, enjoy!


1996 Portofino 20vt & 2000 Pearl White Plus
1985½ & 2016 2017 Fiat 124 Spider + XF Sportbrake
Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619019
16/04/2018 10:53
16/04/2018 10:53
Joined: May 2012
Posts: 1,912
Going North on the A9
dante giacosa Offline
My life on the forum
dante giacosa  Offline
My life on the forum

Joined: May 2012
Posts: 1,912
Going North on the A9
you are very kind- I really appreciate that;

I've asked a question, back on the 'other' thread...

Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619062
17/04/2018 04:39
17/04/2018 04:39
Joined: Jun 2007
Posts: 4,408
Malaysia..Glasgow at heart
Kelv27 Offline
Forum is my job
Kelv27  Offline
Forum is my job

Joined: Jun 2007
Posts: 4,408
Malaysia..Glasgow at heart
Dave, can i include this in the How To section? Credits will go to you of course. smile



Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619064
17/04/2018 06:11
17/04/2018 06:11
Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
DaveG Offline OP
Club Member 311
DaveG  Offline OP
Club Member 311
Forum is my life

Joined: Dec 2005
Posts: 7,123
Lightwater, Surrey, UK
Yes, that's why I did it


1996 Portofino 20vt & 2000 Pearl White Plus
1985½ & 2016 2017 Fiat 124 Spider + XF Sportbrake
Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619066
17/04/2018 06:30
17/04/2018 06:30
Joined: Jun 2007
Posts: 4,408
Malaysia..Glasgow at heart
Kelv27 Offline
Forum is my job
Kelv27  Offline
Forum is my job

Joined: Jun 2007
Posts: 4,408
Malaysia..Glasgow at heart
Done. Thank you for your contribution once again smile



Re: Updated alternator refurbishment post (with pics) [Re: DaveG] #1619068
17/04/2018 07:20
17/04/2018 07:20
Joined: Oct 2010
Posts: 777
London, UK
Serg1 Offline
Club member 436
Serg1  Offline
Club member 436
Enjoying the ride

Joined: Oct 2010
Posts: 777
London, UK
Excellent info.


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