Installed Rebuilt alternator Wiring fried

[Tcash]

How many have installed a Bosch AL75X Remanufactured Alternator and Fried the Wiring due to the B+ terminal being too long and shorting out against the Alternator intake cover?

If you could provide some text and pictures that would be great.

Review thread for more information.
Alternator Type IV (4)

[69BahamaYellow]

Now that you mention it, I just replaced my AL75X OEM 55 Amp alternator with a AL108X high output unit and modified my OEM wiring harness to use with this alternator. My original alternator wiring had never been tampered with, and I noticed the b+ terminal was almost ready to potentially short against the cover, due to the very close tolerance here. the original harness had a rubber boot covering the b+ terminal (see pic below), but it was starting to crumble and the cover had a worn area right over this spot, probably from years of vibration, heat, and thermal cycling. It's probably a good idea to glue a piece of plastic to the cover to give a little extra protection in this area from shorting

[nerdhotrod]

This was so frustrating. I protectively installed a new alternator in my bus.... "1 less thing to fail on a long trip"... I got 200 yards from my house and though my bus was going to burn down.

Oh well.

[skills@eurocarsplus]

installer error. lack of detail....even OEM parts have upgrades/design changes that require thinking. if it was as easy as opening a box and installing the part everyone would do it..

went through this on a 04 (or 05) Volvo. bosch alternator. still charged but had LIN BUS failures. long story short after spending an epic amount of diag time to the LIN BUS I found they had used incorrect internals on the alt.

called the hotline to explain the problem. got they typical "never seen that" from them...pop quiz mother?ucker...you have now, so what about some reimbursement? nope...not gonna happen. treated me like I was some autozone parts swapper

month later, they sent out a TSB on their shitty parts. talking in the Volvo tech circles, 50+ people had the issue. we all got squat from bosch.
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[raygreenwood]

[jakehenes]

I'm gonna jump in. I do this stuff all day everyday it's my job. That being said, I blame parts a lot but it really comes down to critical thinking and looking around in the bay for "what could possibly go wrong" this includes thing that broke just because you breathe on it. I chalk the alternator wire problem up to installer error. Bummer though.
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Owner and mechanic - riverwest auto.

[skills@eurocarsplus]

[raygreenwood]

[nerdhotrod]

Install error?? Please....

The part it manufactured by a reputable company and sold as a direct replacement. When you "directly" replace you short to ground the entire charging system.... It's a subtle contact that you would never know is happening until it's too late and far from user install error.... This is 100% manufacture error.

[Tom Powell]

If you read TheSamba enough you will have seen this as an ongoing problem and "install error" would be appropriate. An inexperienced workman expects quality parts. An experienced workman is suspicious of Empi, Cip1, GEX, brake parts, and alternators. I'm aware of the alternator problem and my '69 camper has a generator. Education and knowledge are what differentiate the individual's assignment of install or manufacturing error. These problems should be corrected by the vendors and not the purchasers. I would assume that in a court of law damages would be awarded and penalties assessed. But, in practicality, we only have TheSamba and the Buyer and Seller Feedback forum.

Aloha
tp

[Abscate]

[nerdhotrod]

This thread is hilarious.

Its install error "because I didn't read the samba enough"… Its install error because you can't relay on the OEM part vendor to build the part correctly…

I work in the automotive industry…. this is not install error. This is a case of a part supplier screwing up. Lets not try to put this back on installer/mechanic that installed the part.

[raygreenwood]

[skills@eurocarsplus]

[nerdhotrod]

The contact point of the stud is very minimal... And once the back cover is on you can't see if where it contacts.... So what youre suggesting is its normal practice to ohm all the connections to ground in the entire changing system when in stalling a new oem part? And please.

This would happen to 100% of the people in this thread that are claiming install error if they didn't read it here first.

[raygreenwood]

[nerdhotrod]

Wow... You guys are right. Install error, I'm done.

[skills@eurocarsplus]

[tootype2crazy]

This is really common. On every one we installed at our shop when I worked there I would measure it and commonly have to cut it down with a cut-off wheel and redress the threads. Can't be too careful on any part you install on old cars these days.
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air-cooled or nothing for me
1978 Sunroof Deluxe Bus (daily driver)
1978 Transporter (mom's, making into a camper)
1970 Single Cab 2.1 turbo/EFI 6 Rib, 78 front beam, vanagon backing plates on rear (project)
2001 GTI VR6 (wife's)

[raygreenwood]

I will say one last thing snd then shut up.... because people either get it or will continue to get their ass burned and cry foul.

There is no denying parts for our,vehicles these days laregley suck in fit snd finish....if not overall quality. You can throw that at the manufacturers. ...and you would be 100% correct......and nothing will come of it. Unless the part is made by a small custom enthusiast manufacturer who owns our types of vehicle and "feels your pain".......out market it too small to get original OEM quality.......at the price loint this industry is willing to afford......so get over it.

As for new parts for new cars.....say an alternator with this same defect.....if there were a rash of failures.....you have the option of complaining....which may actually work because the companies making these are still working to fill vast contracts to the OEMs and want to keep business.......and when you burn your harness on your new GM or whatever.....you can just buy a new one and possibly file a warranty claim (good luck with that)...... its al fixable, replaceble and just money.

On these vehicles. .....you do not have the luxury of not checking parts carefully for defects.....or not having the knowledge or ability or tools to install it right.

It makes no difference if its a part defect......or your fault for not checking it.....or your fault for not installing it correctly. ......because its 100% on you to find the non-existent, no longer manufactured part or parts......that were destroyed when you attached this new or remanned part to your vehicle.

If the whole van burned down......its sti on you and your insurance. No warranty from a part manufacturer is going to find you a new 76 bus.

I am actually surprised that over the years.....when certain parts that are still made for vehicles that are say.....over 20 years old and fit the profile of "hobbyist" vehicles. .....have not had the legal disclaimer slapped on them "for off road use/hobbyist use only" by the manufacturers of the parts. Ray