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Fri Jul 18, 2025 11:09 am

Hello all,

I have been experiencing a repeated alternator failure as noted in the title.

I have a 1994 EJ22 in a 1984 tintop using a Autoventures swap harness.

I had the first failure after 1 year of the swap, it was a factory Subaru alternator, the second failure was 1.5 years after that, and now I just had the third happen.

After the second alternator failure I noticed that the alternator light in the dash was on very slightly at night, but imperceptible during the day. It does react correctly when the alternator is charging vs not and I have an in-dash voltage gauge to back that up. On the most recent alternator I was getting 14.6volts max.

I know that I cleaned the engine bay with water and de-greaser the day before it died most recently, but don't remember if that was a common pattern for the previous ones.

I'm sure I shouldn't be chewing through alternators like this. Any ideas or things to check? Does anything about this situation scream out to you?

My list:
1. engine bay junction box for sending wire connection.
2. alternator connections.
3. Grounds? though not sure what specific ones are relevant in this situation.

Thank you for any guidance ya'll can provide!

Fri Jul 18, 2025 11:16 am

If you're jumping you're van all the time, that might be putting undo stress on the bearings. :lol:

What non-stock modifications have you made to the charging system? E.g. battery cables, hard start relays, additional grounds, etc.

Fri Jul 18, 2025 11:34 am

What alternator, stock for a '94? Those put out 20 less amps than a stock vanagon alt, do you have a high load?
Used or new? Source?
Look up the "big 3" subaru mod. It is a ground wire upgrade strategy. Do you have a ground wire going from the engine to the firewall like stock? Tranny ground strap intact and in good shape?

Fri Jul 18, 2025 12:02 pm

syncrodoka wrote: What alternator, stock for a '94? Those put out 20 less amps than a stock vanagon alt, do you have a high load?
Used or new? Source?
Look up the "big 3" subaru mod. It is a ground wire upgrade strategy. Do you have a ground wire going from the engine to the firewall like stock? Tranny ground strap intact and in good shape?

The original one was a stock '94, the replacements have been Napa 70 amp Remans (was the only one available and needed the van, then they warrantied the first one).

No high loads besides inefficient headlights and SA grill inner lights.

Fri Jul 18, 2025 12:07 pm

I would consider upgrading the alt to something higher than what a vanagon had once you figure out your issue.
https://www.thesamba.com/vw/forum/viewtopic.php?t=601176&highlight=110+amp
Check those ground wires and consider upgrading them as well.

Fri Jul 18, 2025 12:14 pm

I agree with syncrodoka. My EJ22e is running a $40 ebay OEM tribeca alternator that produces 120+ amps. 4 years / 40k miles and no issues - and it constantly has a 50 amp load (dc-dc lifepo4 charger).

Upgraded ground to the alternator leg, starter, and added a 4awg wire from starter to alternator (because that is where DC-DC is pulling power from).

Fri Jul 18, 2025 7:45 pm

I am interested in the Tribeca/ EJ25 alternator upgrade. I see a junk yard run in my future to accomplish that.

For now, NAPA warrantied my 70amp one and I swapped that in for now, headed on a week long trip tomorrow so good enough.

Called my guy at Small Car and discussed the issue. He said the slightly on dash light was likely a diode/regulator issue in the alternator and had see EJ22's chew through alternators. Also talked with my housemate who's a Subaru guy, he's had multiple rebuilt alternators on his EJ25 (in an Outback) that were dead on arrival or very short lived.

I inspected all my big cables and I could definitely go for an upgrade of the battery cables. My starter and engine are well grounded, but the stock ground strap for the battery have seen better days.

I have a list now for sure.

Thanks for all the input!

Sat Jul 19, 2025 1:39 am

Get it rebuilt at an auto electric shop that knows what they are doing. And stop buying rebuilds from Ulan Bator