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#1
08-12-2002, 07:45 PM
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616 alternator brushes replacement
Has anyone replaced the alternator brushes on a 74-76 240D?
Very little room to work but it appears to be even more of a hassle to remove the alternator since the air cond. compressor is in the way. Ideas?
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87 300SDL (115,000mi. 7/1/2008) 03 Jetta Wagon TDI (62,000mi. 7/1/2008) 75 240D(sold, sad to sell it, needed the garage for the SDL!) Smokey 
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#2
08-14-2002, 07:43 AM
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I don't know about your model, but on my 300SD the brushes are removed from underneath the car. On the alternator there is a cable going into a socket, I think it is held in place by a spring clip. Remove the cable first. There are 2 screws holding the voltage regulator/brush holder into the alternator. Just remove the 2 screws and the assembly comes out of alternator and you can replace the brushes. The alternator doesn't have to be moved or unscrewed.
That's the way it is on my car, however yours may be different and I can't help you there. P E H
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#3
08-14-2002, 05:54 PM
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I pulled the regulator on my daughters 78 240d last week and found the brushes way short, yes , size counts. The local auto electric shop suppled new brushes for $1.00. It was an easy and cheap fix although a little tedious trying to hold those small parts and solder them together. I could pull and reinstall the regulator from topside w/o much trouble. Hope this helps as your car may be different but the alternator is probably the same. Good Luck
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 1985 Euro 240D 5 spd 140K 1979 240D 5 spd, 40K on engine rebuild 1994 Dodge/Cummins, 5 spd, 121K 1964 Allice Chalmers D15 tractor 2014 Kubota L3800 tractor 1964 VW bug "Lifes too short to drive a boring car"
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#4
08-14-2002, 09:14 PM
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Well the voltage regulator (w/brushes) came today from FastLane and it only took 5 minutes to take the old one out and replace it with the new one. I came in from the top behind the air conditioner compressor. The new Bosch replacement voltage regulator was more compact (didn't stick out as far) and it was very easy to rotate into place and finger thread the two screws in. The old brushes were worn down to about 1/8" compared to 1/2" on the new ones. Could have resoldered new brushes in but I really like the new regulator and a very simple job! Works like new again!
Thanks PEH, Stevo and TX Bill for the response!
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87 300SDL (115,000mi. 7/1/2008) 03 Jetta Wagon TDI (62,000mi. 7/1/2008) 75 240D(sold, sad to sell it, needed the garage for the SDL!) Smokey
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