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Old 02-27-2008, 07:28 PM
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Join Date: Jul 2003
Location: Alberta
Posts: 268
Bosch Alternator - Brushes Squeaking

I've been trying to track down an annoying squeak from my car for about 6 months. I finally narrowed it down to the alternator.

This afternoon, I removed the alternator from the car and spun it by hand. It squeaked from the back. I figured the bearing was bad, but then I removed the voltage regulator & brush assembly from it, and the squeak stopped!

The voltage regulator is only a couple of years old (I replaced it in March '05). When I replaced it, I kept the old one. So, just to see what would happen, I installed the original regulator. It doesn't squeak. Then I put the new one back in. It definitely squeaks. I repeated this about 5 more times just to confirm that the brushes on the new voltage regulator were the cause of the squeak.

As a final test, I left the old regulator on and reinstalled the alternator back in the car. Sure enough, no more squeak!

While I'm very happy that the squeak is gone, the brushes on the old regulator are almost worn out so this isn't a permanent fix. I'm hesitant to buy a new regulator in case it squeaks too.

Is there something I can do about the squeaking brushes? Has anyone else had the same problem?
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1989 250TD Wagon 5-speed, 160,000mi ::: Dark gray metallic / black cloth
1984 190D-2.2 5-speed, 287,000mi ::: Silver-blue metallic / black MB-tex ::: SOLD
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