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Thread: Just dismantled my failed TD5 Alternator

  1. 19th December 2013, 04:16 PM #1
    PhilipA
    PhilipA is offline Swaggie Subscriber
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    Just dismantled my failed TD5 Alternator

    The second day I had my D2 in March 2013 the alternator failed going to to a club meeting.
    I just pulled it apart today to find that what looks to be the only problem is the brushes are worn out. The D2 alternator has a circular plastic ring around the brushes and it was choked solid with an oily carbon Goop.

    The reason for this I am sure is that oil was coming back from the front camshaft plug for years , as you could click it around with your hand.

    So if you have oil leaking from your camshaft plug FIX IT or you may be up for a new alternator if you want it fixed quickly, or if you are DIY a new set of brushes which should be cheap. ( about $20 from UK) But a heap of labour if like my car some idiot had locktited the Viscous fan on.

    They appear to be the same as Toyota LC brushes so I may try Repco, although There are NO ebay sellers in Australia.
    Does anyone know a source??
    Regards Philip A
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  2. 19th December 2013, 04:19 PM #2
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    djam1
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    Phillip just get one of these

    Defender Discovery 2 5 Diesel TD5 1998 2006 Alternator Regulator Brushbox | eBay

    Yes they are in the UK but I can get stuff from the UK quicker than I can from Sydney
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  3. 19th December 2013, 09:08 PM #3
    PhilipA
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    Thanks mate , I saw them.

    It may not appear to be the case but the two bits are separate. The brush box with brushes is just held to the regulator by 2 screws.

    My regulator I believe is OK, and I saw a post recently that suggested that some of the UK regulators have an additional sensor that cuts down the voltage when hot( more than batteries do anyway)
    I am hoping to keep the alternator as a spare after I have a look at the vacuum pump seals.
    Regards Philip A
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  4. 19th December 2013, 11:19 PM #4
    Thingy
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    I bought brushes and reg from repco. $118
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  5. 20th December 2013, 08:44 AM #5
    PhilipA
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    Outcome.
    I have bought a brush box from UK for $30 including freight.
    The brushes suit many ND alternators as I was able to ascertain that the ones used in D2 TD5 are 100213-2391 and 100213 2530.
    I am pretty sure it is only the brushes as it went intermittent , and would charge normally in between dropouts. When I pulled it apart the brushbox was completely stuffed with goop and one brush protrudes only about 2MM which indicates worn out.
    Regards Philip A
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  6. 22nd December 2013, 02:55 PM #6
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    simonmelb
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    More info here: http://www.aulro.com/afvb/discovery-...ml#post1620615
    Cheers

    Simon
    2003 D2a TD5, ACE, SLS, Vienna Green.
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