TNRabbit

Hey folks~

It's been a while since I posted a question but this one has me stumped. I have one of the Boyle Future Tech souped-up rebuilt alternators (90 amps at idle, 135 max) & it's worked like a champ for over 3 years now. The problem is my alternator like will come on & if I tap on the alternator with a hammer, it starts working again....bizarre? This has worked for about 2 months now, but yesterday it just stayed on & wouldn't go off.

So I took it apart last night to check everything. All looked good but the brushed were pretty worn, but not shot, so I cleaned everything, used DeOxit to clean all the contacts & buttoned it back up. That worked fine for ONE DAY. Now it's back to the light staying on, but it will work for a little while then when I stop & start it again it's back. This is my only vehicle right now & daily driver. I don't know what part is bad, don't have time to send it off, & don't know what parts to replace or what exactly the problem is. Any ideas?

Thanks~

Gary

TNRabbit

Wow.....not ONE single reply??

TNRabbit

I called Boyle; they suggested it was probably the brushes, which were pretty worn when I took it apart last weekend. Just called NAPA & they have them for $4.00. I'll try that.

TNRabbit

I feel warm & fuzzy from all the assistance~

TNRabbit

The brushes looked something like this:



The problem is all the parts stores around here only sell the brushes, but not the plastic holder. I really didn't want to have to do a soldering job on these; didn't I see where someone bought the entire holder assembly in one piece?

TNRabbit

I don't have time to fool around with this thing to find out exactly what is wrong; I just ordered a new 170 amp (75 at 1000 rpm, 170 @ 1800 rpm) alternator from AlterStart, comes with a 1 year warranty for $199--it gets here Friday.



I'm still ordering the brushes & holder from Jacque, & will fart with my other alternator later. Maybe it will come up as a cheap sale here....~

TNRabbit

By the way, removing the entire intake in one piece makes getting to the alternator a PIECE OF CAKE~

Here's what AlterStart says about this unit:

"We supply hioutput alternators and mini starters for most applications, foreign and domestic.

You are bidding on a high output heavy duty 100% NEW alternator, that we have wound to 170 amp capability.

This alternator has been variable speed load tested for performance! This unit has 75 amp capability at 1000 engine rpm and 170 amps at 1800 engine rpm.

Supplied with performance curve chart!

New Alternator - Load Boss IR/IF

170 Amp, 14.4 Volt, CW, 4-Groove Pulley

Used On: (1995-93) Toyota 4Runner, Pickup, T100 Pickup 3.0L

Replaces: Nippondenso 100211-013"

TNRabbit

Pics of the alternator; looked just like OEM.






Got it in & it's working like a champ~

The bakelite piece under the nut was the wrong shape & I ended up using the old one.

snobdds

I know i am late to the party, but every time I have problems with Toyota alternators...it's been the brushes. I know your new one is not a Toyota. I don't have a lot of accessories. on my truck so I stick with the stock alternator.

I have done it both ways...buying the entire brush assembly and the soldering route. It's really not too hard to solder them in. I am glad you got it fixed.

yotarob2005

WOW 170 amps is alot. I thought my 130 amp was going to push the limits of the factory wiring.

thralldad

Just saw this. I would have popped for the $4 brushes! But 170 amps..wow!

TNRabbit

Bought the brushes, too; going to replace them & keep for a spare.

I've run a 2 gauge cable w/150 amp breaker straight to the battery so not worries about the wiring~

amusement

I'm thinking it's time to break out a volt meter and an ammeter. Lastly, you might want to use an ohm meter on those alternator windings. Just to finish this bad boy off. Rectifiers, those awesome AC to DC triacs of fun can also be a hassle from time to time.

I'd have one of those auto parts places test your alternator out if changing brushes don't work.

dropzone

iTrader: (6)

A multimeter will combine All of the above mentioned tools

TNRabbit

It was totally rebuilt by Boyle Future Tech 4 years/32,000 miles ago. The brushes are definitely worn, I'm guessing more than usual due to the high output?

I'll let you guys know what I find out, but it may be a little while.

TNRabbit

UPDATE:

I've been running this alternator now for almost a year with zero issues.

I installed a 2-gauge cable from alternator to battery direct with a 150-amp circuit breaker inline to avoid burning anything up~

TNRabbit

Alternator still working without issue. Old alternator is on the bench as a spare~

YotaCurly

hey rabbit how did you find out what warranty that alternator had im wanting to purchase one for my 92 3vze but cant find how long the warranty is!!

TNRabbit

I don't remember, think it was 1 year. It's still going strong with no problems, almost 3 years later!

YotaCurly

do you recall how much the shipping was !?