Glowing alternator light tonight! Fixed!!!

[VW_Jimbo]

Thank you for the opportunity to expand on my thought. I have reread what I wrote and can see where my train of thoughts did not convey 100%. I am no English major, that is the wife. I am hands on, pictures would be my first choice in communicating. Words are second.

[quote="rockerarm"]

[rockerarm]

[Frodge]

FYI, I use the Wolfsburg West silicone drain gasket and they really work great. Have had the same gasket set on for 10 years or so. The valve covers I have are cork, I've not tried the silicone ones yet.

[Tim Donahoe]

So, if I only have .10 volt difference (one tenth of a volt, if I'm reading the multimeter properly), then it's well within a tolerable loss. And a lower reading at the battery when all accessories are switched on is normal. Correct?

By the way, how do you guys hook up your multimeter to the B+ post on the alternator, then also hook up to the wire coming from the B+ post that is located--and connected to Ta) under the back seat? My wires on my multimeter don't stretch that far. I can only assume that you can use a jumper wire from the B+ post and route it around to where you can tap into it in the cabin. Correct?

Sorry for the questions on this issue, but all the videos I've seen and all the printed, always show, or tell, of the mechanic working on a car where all these connections are located within close proximity of all parts involved, and they're all under the hood.

Tim
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Richard O'Brien

[VW_Jimbo]

[rockerarm]

Tim, Jimbo and myself were correct.
Here is a link from Fluke:
http://www.fluke.com/fluke/uses/comunidad/fluke-ne...sevoltdrop

And from Federal Mogul:
http://www.fme-cat.com/Docs/1519.pdf

[Tim Donahoe]

Allen, I may take you up on the harness thing if I find the voltage drop in the 9mm wire from the B+battery post to the Ta connector.

I was not testing in parallel previously, but will play with it tomorrow--after I sort out the new oil leak.

And Jimbo, from what I've read, that tenth of a volt is five times the limit. Although, that's from a several sources I've read on the web .

.01 to.02 was listed as passable. Over that, and there is some resistance--a connection, whatever. So, I'm going to to a proper voltage drop test to pin it down.

Tim
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Richard O'Brien

[allenw]

I do have an old wiring harness that I have been using the correct wire colors from if anyone needs some correct wire colors. i is about a third gone now.

[VW_Jimbo]

In the grand picture of the charging system a tenth of one volt between the alt and the batt is not a big deal. Divert your attention to sometime more deserving of your time. Go for a drive, adjust your brakes, adjust the clutch or car wash. Heck, come on over and wash my car!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Tim Donahoe]

Fridge, I made sure the oil drain-back passage was clear, before installing the flywheel seal. Plus, I only drove the car about ten miles. I'm sure I'll get at least a small drip as I put on some more mileage. Otherwise, I'm apt to burn out a seal. Probably, the white grease kept the small amount of oil from dripping. If I'm lucky, the new drip is the silicone valve cover gasket. If it's not, then my oil cooler adapter seals may have sprung a leak when I undid and re-tightened the nuts when installing the Hoover bit. If that's the case, I'm screwed. Engine out again . But I'll see tomorrow morning.

The hot, hot days are finally coming to a close. No more 100 degree+ days for awhile.

And Jimbo, I have good numbers but still have a small leak to find in the system. That .10 difference from the alternator, compared to the battery reading bugs me. I did notice some electrical tape on the main harnass in the engine compartment. Hopefully, the previous owner didn't splice something there. I'll use the fast idle cam tip to find out. Thanks.

Tim
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Let's do the Time Warp again!

Richard O'Brien

[Frodge]

[VW_Jimbo]

Great to read a good ending. Glad you were able to complete these tests and that you learned a thing or two in the process.

To check the voltmeter without the wife, you can always use the fast idle cam to hold the rpms up! I did that back before dual carbs!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[Tim Donahoe]

Rockerarm, it's difficult for me to do a complete test without the wife pressing on the gas pedal to get the Rpms to 1500-2000; but at idle I'm still missing .10 at the battery, compared to the B+ post. 14.47 down to 14.37. I'm happy with being over 14, but I'm going to find "the leak", because I'm curious.

With the lights and fan on high speed, this dropped a bit from the battery idle figure (I can't remember the figure right now, but it was also 14.something).

When the wife is here to step on the gas, I'll do a complete test at the higher Rpms. Besides, I spotted another issue.

In the meantime, one of those new silicone valve cover gaskets that I just installed is leaking on me. I put them in, using Permatex Aviation on the cover side (my Gascacinch, which I wanted to use, was dried up). But, I have the good cork gaskets to replace that pos with. Kind of scary since when I noticed the leak on the left side, and I had undone two nuts on the dog house oil cooler adapter to install a Hoover bit. But I don't think the oil is leaking from that event. After wiping the heat exchanger and under the rocker cover, it seemed more like a valve cover gasket issue. I've actually never had one leak like that before, though; but I've never used a silicone valve cover gasket, either.

But, I have no oil leaking from the bottom center of my engine case--where the transmission meets the engine. So, it looks like the new flywheel seal I also just put in is going to be a keeper.

Tim
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Richard O'Brien

[rockerarm]

Hi. I'd be curious if you can detect any voltage drop/loss from the alt B+ stud to the battery's positive terminal, or post.

Even if you had a few tenth's of a volt drop your electrical system may not show any symptoms but as clean as your car is and how particular you are to the details it should concern you.

Simple test. DVOM on DC volt scale, 20v, meter positive to alt B+ stud and meter negative to battery positive post. Start car up and monitor the meter. You cn turn on some items such as headlights, 4-way's, etc in order to get the alt to push some current thru this wire.

Bill

[vamram]

Nice work, Tim! Definitely a great thread to follow. Pics would've been nice...!
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Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
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Save the Supers!!

[Tim Donahoe]

All done! I installed a my new Bosch alternator from Cipi1 (great service from Chris there), and the number I got on the multimeter was 14.47. While there, I also replaced the transmission and battery ground straps with nice copper braided ones from Germany (I got those at Bughaus).

Since I had the motor out, I also replaced the flywheel seal, o-ring, clutch driven plate (the relatively new one had a little grease on it), installed a Hoover bit, painted the fan shroud, breast plate and firewall tins, adjusted the valves (easier when the motor is out, you know), installed new silicone valve cover gaskets from Wolfsburg West (one is leaking a little, but I'll keep checking, and change back to cork if needed), cleaned up a lot of wire connections, and that's about it.

A word of caution: the new Mexican Bosch alternators come with a larger B+ post; so, you'll have to replace the OEM o-ring connector at the wire. Fortunately, my original OEM 9mm wire was long enough so that I got away with crimping a new 1/4 inch o-ring connector to the original wire. And make sure your fan doesn't rub when you put the fan assembly back together. If the fan isn't true, or if you didn't snug down the two small nuts that hold the alternator to the fan assembly, you won't have the required 2mm space between the fan and the fan assembly, so it'll rub.

Okay, now I'm ready for the McCloud, California show at the end of the month.

Thanks to everyone who offered advice. I learned quite a bit of electrical troubleshooting information.

Tim
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Let's do the Time Warp again!

Richard O'Brien

[vamram]

Hey Tim - just caught up with your thread this morning. I don't have much advice, looking forward to reading about the e eventual fix. I'm learning lots about electrical troubleshooting from the great advice you've been getting!
_________________
Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[Tim Donahoe]

Well, I got the new o-ring connector onto the OEM 9mm wire. Silly me, I forgot to put the shrink wrap on the wire before crimping the connector. Duh!

Now, all I have to do is wait until the wife gets home so she can hold the metal fuel line in the engine compartment while I push on the flexible fuel line from under the car.

Funny thing, though: I replaced the clutch driven disc because the old--relatively new one with no more than three thousand miles on it--had a little grease on it. Now, however, my freeplay went from 3/4 inch to 1 and 1/2 inch. Kind of strange, but I'll just adjust it. youd think replacing the new disc with the exact same brand disc with very little wear would not have required but a little, if any, re-adjustment.

Tim
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Let's do the Time Warp again!

Richard O'Brien

[VW_Jimbo]

That's awesome!!! That saved you a lot of headaches!

Right there with you on the hearing! After growing up in a custom cabinet shop with planers, saws, jointer and routers. All of them making high pitch noise. Following that with 12 years of tuning cars, a lot of those night spent at the drag strip tuning a friends vw dragster, also high pitch noises! Add to that my love of hunting and going to the firing ranges. My hearing has suffered. I am okay with my left ear, maybe 70% of what it was 10 years ago, my right ear is at about 50%. I have noticed that I turn my left ear towards people when they talk to me. My kids pointed it out to me one day. Made me stop and start noticing.

Wish I could read lips!
_________________
Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[andk5591]

The connector material is not that important. I buy bulk electrical connectors and almost all are not brass or whatever VW used. Have been using them for many years with no issue. One thing that I ALWAYS do is use external tooth washers on screw together electrical connections to make sure I have a good bite.

Oh one more thing....When messing with the alternator connections, don't let your wedding ring touch the hot wire and a ground. You would be surprised how fast a ring will get incredibly hot in that situation....Not that I have ever done that...
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D-Dubya Manx clone - 63 Short pan,1914.
Rosie 65 bug - My mostly stock daily driver.
Woodie 69 VW woodie (Hot VWs 7/12).
"John's car" 64 VW woodie - The first ever
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