Alternator Upgrade/Rebuild

[Strife]

I got in a more modern 80A alternator with studs instead of the "plug-in" type that came with the 560sl. I got into a sort of an aluminum polishing frenzy and polished the water pump, the alternator mount and the cruise actuator, so I needed an alternator to polish to match everything. The larger alternator (from a late 80's/early 90's 420SEL?) seems like it will fit just fine (After I do a little wiring harness modification).

Has anyone done this?

I disassembled the alternator, and am going to replace the regulator/brush assembly simply because it's old and worn as well as 1500 grit wetordri the copper slip rings and other connections. The housing screws were a #@$@ and required an impact screwdriver to remove. Interesting: I pulled out much of my remaining hair looking for the woodruff key after loosening the pulley. I've since determined that there never was one, although the pulley and spacers are slotted for one and so is the shaft. Am I missing something? Also, the grease looked relatively clean on the bearings and there was a goodly amount of it. I'd like to clean/repack the bearings simply on principle. Any advice on the type of grease to use?

[samiam4]

I would not use wet/dry sand paper on the armature.

I believe abrasive will embed in the copper slip-ring which will give you a reduced life on the new regulators. Gennerally, most ppl just put a new reg assy on the alternator and go.. after the second regulator change, they buy a rebuilt. I've not seen an brg failure.

If you've got it apart- simply turn the copper slip ring by putting the armature in a lathe.

Michael