I went through 2 el crappo "lifetime warranty" rebuilt units in as many months on my last car (85 300TD). The first one had bad rectifiers that went in about 2 days, so I pulled it and replaced it with... the second one that had a bad solder on the voltage regulator and failed 2 weeks later. So, I pulled it again and replaced the regulator with a spare I already had. Two months later all four case screws backed out while on the highway and caught in the fan blades on the pully, causing it to seize and melt two belts in about 30 seconds. So, I pulled it AGAIN and removed the bolts, added lock-tight and reassembled. I didn't want to exchange it for fear of getting another one with bad electronics. Fortunately, I had bought replacement belts earlier and had been to lazy to replace them.

But all that is beside the point. It just sets the stage for my distrust of lowest possible bidder, third world, zero quality control, "life-time warranteed" rebuilt parts.

I picked up a "new" car (84 300TD), that is not charging. I haven't had an opportunity to do a full diagnosis yet, so it may just need a voltage regulator. But in the mean time I did take a quick peek, and it appears to still have the original alternator (bosch with a mercedes star on the label).

So, does anyone know of a shop that can do a quality rebuild on my original alternator? (Assuming that I determine that it needs it.)

I'm near New Haven, CT. Local would be better, but I could ship it if I have to.

Look in the local Yellow Pages, or do a search on-line. Nearly every decent sized city (and New Haven would definitely count) will have electric machine rewind and rebuilding shops. Maybe someone from the area will pipe up, but I would think finding a qualified repair shop should not be a problem for you at all. Good luck.

Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

You have to ask around. At this point, maybe it would be best to go with a dealership if you don't know anyone. Local doesn't mean it is any better than overseas. Ask me how I know. I bought 2 heated seat covers from Phil and within a year, one of them failed. Took it to the local MB shop and they warrantied it and even installed it for free.

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

The outcome of a local repair shop rebuilding the alternator is really dependent on the problem. If the basic windings are sound, a local guy can repair all the rest of the mechanical and electrical items displaying signs of wear. I doubt a local guy would actually rewind the machine as these things are done on purpose built machines that are not normally part of a local repair shop's typical set of equipment. So, they would send it out for that. By that time the bill would dwarf the cost of a new unit from the dealer.

My local guy (Groton Auto Electric, in Groton, CT), who I haven't used in quite some time, would do some tests to check the windings and if they were weak, he would tell me he recommended a rebuilt unit from Bosch which he would gladly supply at about the dealer pricing. If the windings were ok, he would go ahead with the repair, which involves new bearings, turning the commutator bars down to be concentric with the bearings and smooth, replacing the diode wheel, and cleaning and repainting the body/frame. He ran a test afterward at rated current and voltage for long enough to get the unit too hot to touch, and then megger checked the windings again, hot. If all was ok, I got the unit back. In the old days he would do this in an afternoon for me and charge about $65 to $95, depending on the alternator and what really needed to be done. I have no idea if he is still in business or what his prices might be today.

I think these kinds of shops used to be all over, but maybe the cheap rebuilds are putting them out of business.

Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

How would the basic windings not be sound? I suppose if it crashed into the rest of the alternator. Doesn't the windings just go around and around but not touch anything?

__________________
01 Ford Excursion Powerstroke
99 E300 Turbodiesel
91 Vette with 383 motor
05 Polaris Sportsman 800 EFI
06 Polaris Sportsman 500 EFI
03 SeaDoo GTX SC Red
03 SeaDoo GTX SC Yellow
04 Tailgator 21 ft Toy Hauler
11 Harley Davidson 883 SuperLow

I highly recommend using the remanufactured Bosch alternators you can purchase through Phil at FastLane. Here in Austin, they are the same product the dealership uses when they install a remanufactured alternator.

About three years ago my alt failed and I had it rebuilt by a (formerly reputable) rebuilder here in the Austin area. The remand alt lasted just over 6 months before failing...pulling the regulator revealed an 80-grit finish the rebuilder had applied to the sliprings. This crappy work caused premature wear of the brushes on the regulator.

The local warranty was pro-rated (surprise) so, I was in for another $60-$70 and a crap shoot on the quality or, spend 2x that and get one from Phil. I opted for getting the part from Phil. It's performed perfectly ever since.

The local rebuilder used to be much like the shop Jim described: excellent service, great work, etc. Apparently, things have changed because the place now looks like a clothing sweatshop in Macau, filled with SE Asians at rows of workbenches, doing spray-n-pray rebuilding on alternators and starters.

__________________
Never a dull moment at Berry Hill Farm.

Heat is the enemy of all things electric. Insulation materials break down, especially when they get covered in a layer of grease and dirt as the temperatures get higher and higher. There is an "old rule of thumb" that says insulation life is cut in half for every 10 degrees Fahrenheit increase in operating temperature. So a dirty, oil soaked alternator with road dirt stuck to it is going to run hotter than intended and eventually the voltage will begin to bleed across the insulation and make its way to ground. That usually adds heat to the mix and speeds up the insulation system demise. Jim

__________________
Own:
1986 Euro 190E 2.3-16 (291,000 miles),
1998 E300D TurboDiesel, 231,000 miles -purchased with 45,000,
1988 300E 5-speed 252,000 miles,
1983 240D 4-speed, purchased w/136,000, now with 222,000 miles.
2009 ML320CDI Bluetec, 89,000 miles

Owned:
1971 220D (250,000 miles plus, sold to father-in-law),
1975 240D (245,000 miles - died of body rot),
1991 350SD (176,560 miles, weakest Benz I have owned),
1999 C230 Sport (45,400 miles),
1982 240D (321,000 miles, put to sleep)

Another choice might be the rebuilder with perfect feedback located in california. Perfect feedback is hard to earn in that field so he must be serious and pretty competent.
His prices are usually 59-69 for alternators and you supply no core. He first attracted my attention with his 69.00 rebuilt 123 mercedes diesel starters. Again with no core required. His shipping is reasonable as well.
On a somewhat more sertious note. One ongoing problem in the starter/alternator repair business is the poor quality of aftermarket replacenent parts. It is just hard to get good replacement parts of reasonable quality for rebuilding/repair purposes at reasonable prices. Although some repair/rebuilders still try. An example is the regulators for 123 alternators. The bosh are still pretty good the off brand regulators are of questionable quality.
Disclaimer: I have no business connection or other interactions with this guy. Not even any involvement with his wife.

What really bothered me was the several small three to six man shops I examined did not even have enough equipment to establish if the stators, fields, etc were electrically balanced. When one brush is shorter than the other you have an electrical balance problem in the alternator .
As for the bosh slip rings. They are changable. The part is not expensive and is part of a good repair if they are worn. If not too worn a small clean up cut is allowed.
The way the overall market is today small quality repair shops are going to get very scarce soon. One noticable benifit of purchasibg a bosh rebuilt is you should be getting bosh replacement parts. A few years ago I purchased two mexican rebuilt starter/alternater units. There will not be a third one.

There's a local alternator rebuilder in Grand Rapids, MI called M-Brand. I have one of his alts in one of my domesticated cars and seems to have lasted a while. Phone: 616-243-9547.

The should one similar in your area. Check your yellow pages under Alternator-Automotive.

__________________
the sooner you start... the sooner you'll get done If it ain't broke, don't fix it.. Its always simpler to tell the truth...
2007 Honda Accord EX
2007 Honda Accord SE V6
96 C220
97 Explorer - Found Another Home
2000 Honda Accord V6 - Found Another Home
85 300D - Found Another Home
84 300D - Found Another Home
80 300TD - Found Another Home
Previous cars:
96 Caravan
87 Camry
84 Cressida
82 Vanagon
80 Fiesta
78 Nova
Ford Cortina
Opel Kadet
68 Kombi
Contessa

You can find a Bosch Dealer/Service Center in your area......I have had great results....my old tractor has all Bosch electrical stuff.....the folks at Bosch USA helped me locate the second last Starter Bendix in the USA....all $350.00 worth....for my particular application please note that the parts that I needed are quite rare here in the USA as the Eicher tractor Club in Fornstern, DE still has a question as to how my tractor got over here, as there was never a dealership in North America......

here's a link... http://www.boschautoparts.com/Products/AlternatorsandStarters/PP+Alternators.htm

SB

__________________

Diesels:
'85 300D, "Max, Blue Benz", 155K, 27.0 MPG
'84 190D 2.2, "Eva, Brown Benz", 142K, 40.2 MPG
'77 240D (parts car)
'67 Eicher ES 202 Tractor "Otto" (2cyl, Air Cooled, 30HP)
Gassers:
'94 Ford F-150, "Henry", 170K (300 Six) 17.5 MPG
'85 190E 2.3, 148K....Parts Car
'58 Dodge W300M Powerwagon (Flat Fenders) Less than 10 MPG

Their is one in Milford right off exit 40. I know where they are but I cannot think of their name off the top of my head. You would be coming south bound, you get off at exit 40, take a left. Cross Old Gate Ln, going through the 4 way intersection on Woodmont past Pilot Truck stop. The shop is right by the first light on Woodmont on the right. I can't think of their name off the top of my head. But all they do is rebuild electric motors and they have a good reputation. I am going to have them do the SDL's starter eventualy. They did the starters and alt's on my grandfathers boat.

Found them!
Barbin Electric Inc
45 Eastern Steel Rd
Milford, CT 06460

(203) 878-4629

__________________
1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

Hattie,

I thought there was one in Milford, but I couldn't find them. I knew you'd be the one know.

Thanks man.

Anytime. Are you planning on coming to the GTG?

__________________
1999 SL500
1969 280SE
2023 Ram 1500
2007 Tiara 3200

I'll see you there.