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DanHoug
Samba Member
Joined: December 05, 2016
Posts: 5897
Location: Bemidji, MN
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 Posted: Fri Oct 13, 2023 9:06 am Post subject: Voltage regulator rebuild |
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well, this is just silly... why rebuild one when you can buy a new regulator for $16? maybe you don't want more Chinesium parts installed, maybe you don't like throwing things away, maybe you think a 35 year old regulator made in Germany is better quality. matters not, it's easy to do and cost a whopping $5.99 for a quality set of brushes.
old and new brushes. easy to unsolder with a solder sucker, wicking braid, or the Hakko FR300. a 250 watt soldering gun works great.
put the spring on and thread the needle. these brushes have a nib to keep the spring centered, like the OE ones, and a scribe mark on the side of the brush to determine the brush lead length.
hold the brushes at the proper depth with a bit of tape. note scribe mark.
solder in place, just enough to cover the hole, too much and the brush lead wicks the solder and becomes stiff. then flood the flat part with solder to really bond it down.
finished product with scribe mark showing.
good as new, unavailable Made-in-Germany regulator!
Note: Dave's Volvo Page is a wealth of information, videos, and parts for Bosch alternators. He shows a very easy regulator test procedure that allows you to determine the voltage set point of your non-adjustable regulator.
https://www.prancingmoose.com/AdjustableVoltage.html#brushes
i bought the 8x5x19.5mm brushes from Maniac Electric Motors, a standup place that immediately corrected an order error. he also sells everything needed to rebuild the alternator... bearings, bearing cups, slip rings, etc.
https://www.maniacelectricmotors.com/73201115b.html
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com
Last edited by DanHoug on Fri Oct 13, 2023 1:08 pm; edited 1 time in total |
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ALIKA T3
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Joined: July 30, 2009
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Location: Honolulu,Hawaii and France
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jlrftype7
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Joined: July 24, 2018
Posts: 4762
Location: Chicago
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| Posted: Fri Oct 13, 2023 12:04 pm Post subject: Re: Voltage regulator rebuild |
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Outstanding work- Even if new ones are available, can we make this a sticky or something similar, so we don't lose this info... 
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E1
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Joined: January 21, 2013
Posts: 8636
Location: Westfalia, Earth
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| Posted: Fri Oct 13, 2023 12:05 pm Post subject: Re: Voltage regulator rebuild |
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Yeah, pretty ingenius, Dan!
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ZsZ
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Joined: December 11, 2010
Posts: 1743
Location: Budapest Hungary, Europe
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| Posted: Fri Oct 13, 2023 12:06 pm Post subject: Re: Voltage regulator rebuild |
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My Father in law works in an alternator and starter rebulder shop. They do re-brush old regulators, as the new ones are not so reliable as the OE ones were. Even the new Bosch ones which are nowadays made all around the world except Germany.
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ALIKA T3
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Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Sat Oct 14, 2023 12:41 am Post subject: Re: Voltage regulator rebuild |
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| ZsZ wrote: |
| My Father in law works in an alternator and starter rebulder shop. They do re-brush old regulators, as the new ones are not so reliable as the OE ones were. Even the new Bosch ones which are nowadays made all around the world except Germany. |
Bosch are made in India, like their Temp 2 threaded sensor 
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djkeev
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ZsZ
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Joined: December 11, 2010
Posts: 1743
Location: Budapest Hungary, Europe
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| Posted: Sat Oct 14, 2023 4:33 am Post subject: Re: Voltage regulator rebuild |
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| ALIKA T3 wrote: |
| ZsZ wrote: |
| My Father in law works in an alternator and starter rebulder shop. They do re-brush old regulators, as the new ones are not so reliable as the OE ones were. Even the new Bosch ones which are nowadays made all around the world except Germany. |
Bosch are made in India, like their Temp 2 threaded sensor |
Or Taiwan, Spain, GB, or even here in Hungary
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Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008 |
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DanHoug
Samba Member
Joined: December 05, 2016
Posts: 5897
Location: Bemidji, MN
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| Posted: Sat Oct 14, 2023 6:11 am Post subject: Re: Voltage regulator rebuild |
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right. i like the voltage setting on the one in your link... 14.5v instead of the typical 14.1 given the waffling disclaimer in the Product Description, it'll be interesting to see if you are sent a German one or that it "comes from a German company that has manufactured that component at a facility that is owned by them, and it is made to their high standards of quality and fitment." keep us posted! searching for Huco regulators, i'm returned photos of them made in India and China plus the one made in Germany per your link.
the argument can justifiably be made that with a part so cheap, just carry a spare, which everyone should. for me, it turns into a matter of convenience... if a cheap part fails quicker that means an unscheduled repair somewhere not under my choosing. but alas, we haven't proven that a $15 part actually fails faster than rebuilt vintage part. well, we have with coils, points, caps & rotors, fuel pumps, suspension parts, and rubber bits but so far not regulators!
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Sat Oct 14, 2023 10:08 am Post subject: Re: Voltage regulator rebuild |
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| DanHoug wrote: |
right. i like the voltage setting on the one in your link... 14.5v instead of the typical 14.1 given the waffling disclaimer in the Product Description, it'll be interesting to see if you are sent a German one or that it "comes from a German company that has manufactured that component at a facility that is owned by them, and it is made to their high standards of quality and fitment." keep us posted! searching for Huco regulators, i'm returned photos of them made in India and China plus the one made in Germany per your link.
the argument can justifiably be made that with a part so cheap, just carry a spare, which everyone should. for me, it turns into a matter of convenience... if a cheap part fails quicker that means an unscheduled repair somewhere not under my choosing. but alas, we haven't proven that a $15 part actually fails faster than rebuilt vintage part. well, we have with coils, points, caps & rotors, fuel pumps, suspension parts, and rubber bits but so far not regulators! |
I did receive it, that's why I posted, it's written made in Germany on the product AND the box, with a JP Group label stuck over the box.
Doesn't mean much these days, some components could very well made in Shitland and boast the made in Germany bc more than a certain percent of the parts are made and assembled in Germany...
Fits and works great so far. Customer is happy. Let's see if it lasts 35 years, but I doubt it...
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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DanHoug
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Joined: December 05, 2016
Posts: 5897
Location: Bemidji, MN
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| Posted: Sat Oct 14, 2023 10:39 am Post subject: Re: Voltage regulator rebuild |
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just for posterity of thread documentation, this is what is under the black plastic cap. stamped Bosch but it would be interesting to know if they made these themselves or rebranded someone's part. i wish all these old farts that were design engineers back in the day were online now to tell us how it was done. prolly all dead by now.
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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bobbyblack 
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Joined: May 21, 2015
Posts: 4682
Location: United States, Iowa
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| Posted: Thu Sep 12, 2024 11:25 am Post subject: Re: Voltage regulator rebuild |
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| DanHoug wrote: |
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hold the brushes at the proper depth with a bit of tape. note scribe mark.
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Well, I know if I had my Bentley manual handy, I could find the proper depth. Maybe it depends on other elements, but if I were reading this thread while trying to follow your walk through, I'd also really appreciate what the proper depth might be.
Thanks,
-bobby
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DanHoug
Samba Member
Joined: December 05, 2016
Posts: 5897
Location: Bemidji, MN
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| Posted: Fri Sep 13, 2024 2:28 pm Post subject: Re: Voltage regulator rebuild |
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| bobbyblack wrote: |
| DanHoug wrote: |
...
hold the brushes at the proper depth with a bit of tape. note scribe mark.
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Well, I know if I had my Bentley manual handy, I could find the proper depth. Maybe it depends on other elements, but if I were reading this thread while trying to follow your walk through, I'd also really appreciate what the proper depth might be.
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to directly answer, 10.5mm extending beyond the porcelain to the outside edge of the brush that has been pre-radiused.
but the CORRECT brushes will be scribed with the index mark as seen above you simply insert and solder the lead to the depth of the score mark. no measuring needed.
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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