RIP: Alternator #5

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Ok... this is getting a little bit ridiculous. this is my second alternator to fail in 4 months. my 5th since i rebuilt the car in 08.

It failed in the same way as all the others, what ever mechanism is used to internally dictate how much energy the alternator is putting out got stuck on the full blast position. lighting up my dashboard like a Christmas tree and doing its very very best to cook the hell out my red top.

It was such a heavy and sudden surge this time that it blew out my low beam bulbs. Yea..


my battery is mounted in the trunk & I know my 3inch down pipe is very close to the alternator and oil filter. Those are the only things i think are relevant to this problem.

what can i do to stop killing these %@^#ing alternators. is their anything other than heat that it could be?

 

[DSM nOOb]

do you have a circuit breaker on your power cable within 12 inches from the battery?

 

[Rob10_99]

That much of an issue I wouldn't consider a heat problem, more like high resistance or shorting.
Check the resistance from the battery to the case of the alternator, and the positive "charge" lead to the battery.
What gauge wire is running to the rear battery? check that resistance, should be fairly low!
Any sound system on your car? That could cause issues with a remote battery setup as well.

What is your idle voltage at the battery/alt output as well?

 

[standard235]

The voltage regulator burns up. My cousin went through a bunch of NeverLast's from parts stores. He had the gains on his stereo set up wrong and it was pulling his voltage down to like 10V on big bass drops, which is HARD on the alternator.

Get it rebuilt bigger and stronger if that is what you have going on. If it's a stock electrical system other than the relocation with the RedTop, then look into a heat shield for the alternator or something. Heat is what kills the regulator.

 

[endeffect0]

First of... what the heck are you guys doing up.. I am greatfull for the help, truly.. but still.


Ok, yes to the inline breaker, 150 amp actually mounted to the 'hat' ontop of the red top.


No to any electrical abuse. I dont have a sound system, its all just daily and rallyx duty. Note that the down pipe does get to glowing red at rallyx events.

I dont remember the gauge of wire off the top of my head. But it was over kill. It was the largest gauge battery cable that i could order from the local parts store.

No non stock sound system in my car.

Ohm testing the setup will be difficult just due to the length of wire... but it makes good sense. I will try to find a way to do it.


thanks for your suggestions guys.

 

[steve]

Given what you've said so far is clear that the voltage regulator in the alternator is failing and your likely cooking them. Even a little metal shield between the alternator and the downpipe can make the difference between life and death. You can try wrapping the downpipe too.

As long as there isn't oil or power steering fluid dripping into the alternator it sounds like a heat problem.

 

[GooeyGus]

I went through 5 in about two years as well. REMEMBER TO KEEP THOSE WARRANTY RECEIPTS!!!

My record for an alternator death was 13 DAYS. I brought it upon myself, because as I was walking out of the auto parts store with my new alternator, I said "hopefully I can get this one to last for more than a couple weeks". 13 days later it was dead.

I just kept replacing them and eventually I ended up with one that has lasted for almost two years now. BUT it has just started to get a bit "iffy" at idle. The lights are starting to pulsate a bit anywhere below 900 RPM.

I've just come to accept that alternators on these cars need to be changed a lot, and if i can get a couple years use out of one, I'll be happy. The last time I actually bought an alternator for the car was about 6 years ago, I just keep the receipt and walk in and exchange it when it goes bad. I can have it swapped out in 10 minutes now, hahaha.

 

[standard235]

Get one from NAPA... you won't regret it.

 

[One Equals Two]

I put two heat sheilds on mine and used an OEM alternator. So far no failures in 4 months, compared to 3 Duralast's in 5 months before.

 

[endeffect0]

I went through 5 in about two years as well. REMEMBER TO KEEP THOSE WARRANTY RECEIPTS!!!

My record for an alternator death was 13 DAYS. I brought it upon myself, because as I was walking out of the auto parts store with my new alternator, I said "hopefully I can get this one to last for more than a couple weeks". 13 days later it was dead.

I lost em!!!


Arghhhh. But i called the autozone and they said if i can call the store i bought it from they could give them a transaction number and they could put it though. so now i just need to find the one that has it in stock thats closer than 90miles that i got the first one from.



I am really glad to hear that i am not the only one with these issues. heat shielding will be happening today. i am going to make sheild with a sandwich of fiberglass between two layers of sheet metal. I am thinking of wrapping the down pipe.. but i dont know if i like header wrap where it will get wet. thoughts?

 

[standard235]

Ceramic/jetHot coating is really good for this. Turbine housing/O2 Housing/Downpipe... reduced underhood temps ftw

 

[american-rice]

I had the same thing happen a few weeks ago, high beams and low beams toast. When I got it checked they said it was fine. Since I bought my 1G I'm onto my 3rd alternator in a year! Sounds like a good idea to shield the alternator. Does anyone have a picture of one they have fabricated?

 

[DSM1G90]

Ah...AutoCRAPzone stuff rules again!

You'd be better getting an alternator from Radio Shack (if they ever sold such items like that..) than that place..

Goto NAPA as suggested ...

 

[turbo90gsx]

Sounds like you keep replacing the bad alternator with the same type. All company's that re-manufacture alternators and such take short cuts.

However when an engine is removed from a vehicle the posiblity of wire getting damaged is greatly increased. Especially when componets are re-located. You should double check and verify your harness did not get pinched anywhere. Start narrowing down things that it can not be.

 

[endeffect0]

I have gone thought just about everything in the egninebay, all major connections are clean.
I think its just the heat.

and yea. advanced is crap. if i had the money i would go somewhere else. till then i will just keep doing the free replacement on their life time warranty.

it would be cheaper for them if they just made a good product, but whatever.

 

[97gstjosh]

you are def not alone my friend im on alternator #4 from autozone in a 3yr period.. I havent paid for one in 3yrs though hahaha it gets annoying replacing one every year though... so unless it bothers you just keep getting them from wherever you can get them free

 

[endeffect0]

wow i had no idea this was such a common problem... crazy

I will just go get a free one. Regrettably the very same friends who's cars i am constantly fixing in my own garage and on the side of the road. are very successfully making themselves completely un available by sitting infront of the TV for the last two days.

it is insanely frustrating that none are willing to drive the 10 miles to pick me up and or just let me borrow their car to go and get parts. trying to remain civil. But i need to get to work on monday.

 

[MITSUMURDOK]

Do yourself a favor and find a good auto electric shop and get an alternator from there. I picked one up from a place by me for like $130 and it put out more amps than stock. I've had it in my car for 4 years now without any problems and I have a system (nothing crazy-2 12's and components--2 amps). I just picked one up from there for my 95, those junk alternators from autozone or advance or any of those places will never last. I've been dow that road too many times to ever trust a junk alt. ever again.

 

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completely agree. but for now, due entirely to lack of funds i am going with the free one.

 

[a95gsx]

wow i had no idea this was such a common problem... crazy

Like you mentioned heat and crap replacement parts.

I've had the same alt since when I bought the car back in the late 90's and I am pretty sure it is the origional. That's over 140k miles on it. I've still got both factory heat shields on the car. The downpipe is wrapped with thermo-tec too. Fab something up to keep a bit of heat off the wretched things.

 

[endeffect0]

Ok drove the 100 mile round trip to get one in a car i stole from a buddy. people keep forgetting i have spare keys . I was pissed he wouldn't get off his butt on his weekend off to pick me up so i just rode the bike the 10 miles to get his jeep.

kinda need the exercise anyway i suppose. I returned it with a full tank an parked it on a huge mound of snow for good measure. im sure he will have no problem getting down being as i installed his lockers for him a week ago.


Aside from having only one alt in a 50 mile radius advanced auto was very cool about the swap. I just walked in handed it to the guy and told him i needed another. he looked up my receipt by phone number and I was back on the road before the song on the radio had changed. good folks at that store, even if the parts are cheap.


Im going to fab up a head shield in the morning. Ill let you guys know what i come up with.

 

[steve]

At the rate your going you might want to get a spare to save you that long ride in the future.

 

[1997_GSX]

Thought about the Saturn ALT Swap? I did It, I like it.

They also have integrated pulley fans

 

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both valid points. right now they are free. but it could sill leave me stranded some time. I am going to look into the saturn swap. but for now i will see how the heat shield works out.

I severely underestimated how cluttered and tight that region of my engine bay was.
I could find no way of creating a heat shield that would not need to be removed if i need to replace the alternator should another one fail. the plan of action at this point will be to simply buy a header wrap and wrap my manifold as well as the down tube. I have also added a fresh air duct, in the forum of a tube from the abandon fog-light mounts to direct cool air at the alternator.

 

[DSM1G90]

They also have integrated pulley fans

"Psst!" Mitsu ALTS have their fans located internally and at the rear, not in front and outside like the GM ALTS.

Also, with Mitsu ALTS, hit the carwash once in a while and hose down the ALT to keep it clean, esp the vent holes in front. Nothing aint going to blow up, short out, or go "poof" when you do this.

-DSM