I debated whether or not to post this here, or on the electronics board, but I am a V6 guy, so here goes. I have a 92 RS. Everywhere I look, GM shop manual, ALLDATA, and Hayes, they all say the alternator/generator is not rebuildable and must be replaced as a unit. Now I know this has gotta be BS because reman units are readily available. Saturday, my unit took a dump and I was forced to buy a Pep Boys special.
The one I took out I wish to keep and rebuild because it was rewound to put out 140 + amps. I installed a custom high-end stereo system for a co-worker and as partial payment he had his cousin beef up my original unit. The cousin has since sold his business and I'll be damned if I return that core to Pep Boys for a lousy 25 bucks!!! If anyone knows how or where I can get the info I would really appreciate it. Thanx in advance.

 

My manual shows you can take apart and replace brushes, voltage regulator and diode. Kits cost around $35.

Check this link for the repair kits:

http://www.autozone.com/R,2017913/ve...ductDetail.htm

 

Thankyou for your reply. I have seen that rebuild kit at Auto Zone. Which manual are you refering to? I have both the Hayes and a reprint of the original GM shop manual for the 92 Camaro. Both state that the alternator/generator must be replaced as a unit as dissembly may cause damage to the unit. Does the rebuild kit come with an instruction manual for unit dissembly? Thanks again in advance

 

In the Haynes on page 5-7 section 13 it shows you should be able to use a paper clip inserted in the small hole in the back to hold the brushes in. Scribe a mark on both back and front to make sure you reassemble it properly, then remove the four bolts. And more detail about the inside brush and regulator replacement, as welll as the rectifier bridge.

My GM shop manual says what you have stated in your post. Alternator cant be serviced.

I am about to disassemble mine so I can repaint it, looks like it has been left out side for a year. I am going to give it a try as soon as I get the front fan off. Should have it done in a week.

 

Haynes also says that 87+ alternators cannot be rebuilt. What you are talking about is the older system SI (system integrated, using internal regulator, first generation) alternator. 87+ have the newer-generation CS alternator, which most technicians refer to as the "Can't Service" alternator. I've tried it myself, after having taken classes where we learned to rebuild alternators, and, while it can be done, it comes up in the uber-difficult category. Once you get yours open, you will see for yourself the difference between your alt and the one in the Haynes manual... You can find parts and instructions online, but you're better off replacing it for all of the labor and money you are going to put into your project.

Oh, and if you search through one of my older posts, either here or in the Electronics section (if the crashing of the server didn't lose the data) you will find a link to parts and instructions.

 

FUNIROC, you are referring to the older SI unit which has four throughbolts holding the two halves of the casing together. Mine has three throughbolts which is the newer CS unit that Maverick H1L is talking about. I still wish to tackle the project. This alternator has been apart before and beefed up. I do not want to settle for a unit with only 100 amps (at most) of output, especially with the current draw requirements of my audio system. Maverick H1L I will try another search on the topic specifically looking for your post. Your link to the parts and instructions should be most helpful. Thankyou

 

FYI, it's not my link... I believe Gumby or someone gave me the link that I have long since lost between 3 computers... And good luck with the search... While switching between servers and forum systems, the guys who run this site have totally messed up the search system (it's NEVER worked right for me since the big crash).

:edit: I did an outside search and found this:

http://www.alternatorparts.com/cs130_sbpage1.htm

Here's the CS service manual, and links at the top of the page have parts.

 

u can try edison generator on route 1 in edison for parts info or drop off for rebuild

 

MaverickH1L, thankyou. That is exactly what I was looking for. FELL231, thankyou also for your info. I work in Sayreville. I could easily stop into Edison Generator for the parts I need

 

If you go to that link I gave you, you can find another upgrade kit for your alt. it's listed under both the kits and repair parts pages, and it's called the Iceberg kit. i just might do this myself sometime...

 

I have already printed out the six pages of the link you provided and added it to my shop manual. You have me interested in this upgrade kit I will head back to the site and hunt around for it...

 

Hey Maverick H1L. I went back to the site and looked around. There is some really cool stuff there!!! I am especially interested in that huge external rectifier bridge they offer for the GM CS series alternators. The iceberg kit you are talking about looks pretty sweet. I already have the larger windings in my unit. I could use the iceberg repair kit since the rectifier is what took a dump in my unit. That external rectifier is really looking good to me as well...

 

Well I got the alternator apart. Was not bad at all really. I can see it being difficult for someone who does not have alot of experience undoing crimp and solder joints. Seperating the stator winding from the rectifier bridge was the most difficult/tedious. MaverickH1L the link to the instructions you gave me are priceless Let you know if I go for the externally mounted rectifier bridge or the monster external puppy and how they work out! Gonna put them on my Xmas list LOL

 

let me knwo how it turns out, i live in sayreville and have an alt that was wound to 120 amps that is starting to go out on me. would gladly pay to have it rebuilt