D3 Dramas

**andylandy** · 27th June 2015, 10:34 AM

Well, had some fun yesterday, the wife, my mum and the 3 kids went off in our D3 yesterday morning for a bit of shopping, 10 minutes later I get the phone call, were stuck and the car has no power and I can't even turn the hazard lights on! Told her to get kids out and somewhere safe and I'd be there soon. Threw some tools, recovery kit, IID diagnostic tool and my Dad in my trusty D1 and off we went.

D3 was stuck at the busiest junction in Penrith and causing some traffic Queues, had some fun in getting through the traffic to get to her, but tried the key and nothing no dash lights nothing! Checked the battery 2.3 V!!! tried jumping the D3 got dash lights etc but no way was it starting, just getting a click from the starter, but had enough power to get the car out of park and release the handbrake. Disconnected the battery, and towed the D3 out of the way, had wife directing traffic in fluro vest, Dad driving the D1, and My Mum looking after kids!

Once in a safe spot did some checking, and found open circuit to starter/Alternator wire, was pretty confident that it was the alternator, so at 1pm phoned NRMA to flat bed the car home, phoned KLR Automotive and they sourced me a new genuine alternator. And whilst waiting for the flatbed had the D1 charging the D3's battery to try and recover it.

Got the D3 home and pulled out the old alternator, went and picked up the new one, and stuck it in. Car back together and running by 7pm, all faults cleared with no issues. Battery was on charge from when we got home on the flat bed (3pm) until 7pm.

Checked the battery this morning and holding 12.3 V, and started the car just fine, so looks like the battery escaped terminal damage!

So all in all a fun day! Pulled the plastic cap off the old alternator this morning and this is what I found! I broken connection with evidence of arcing below the connection, this allowed the alternator and in turn the battery to connect straight to earth!

The joys of D3 ownership

Cheers
Andy

**jonesy63** · 27th June 2015, 11:16 AM

Another victim of a stupid LR engineering design for the fuse to the alternator.

**AnD3rew** · 27th June 2015, 02:05 PM

Yep, mine did the open circuit going as well and took out a brand new $500 battery with it.

LR should be ashamed of themselves for this. Really dangerous in a 4wd vehicle.

**Wasa57** · 27th June 2015, 02:20 PM

Andy, petrol or diesel? (Either way, lucky to avoid fire!)

If TDV6, how hard to change the alternator?

-Wasa

**rar110** · 27th June 2015, 09:42 PM

Well done identifying the cause so quickly.

**andylandy** · 28th June 2015, 07:19 AM

Originally Posted by Wasa57

Andy, petrol or diesel? (Either way, lucky to avoid fire!)

If TDV6, how hard to change the alternator?

-Wasa

Hi Wasa,

TDV6, not hard at all, there's a bit of work involved, but if you can spin a spanner then you'd have no problems. The hardest parts were removing the viscous fan ( I have a fan spanner but had to make a tool to hold the pulley) and taking the plug off the back of the alternator, ended up compressing the little latch with one hand and using a long handled screwdriver to push the plug out with the other hand as couldn't do both at the same time with one hand, and there's no room for 2!

Cheers
Andy

**AnD3rew** · 28th June 2015, 08:57 AM

Originally Posted by andylandy

Hi Wasa,

TDV6, not hard at all, there's a bit of work involved, but if you can spin a spanner then you'd have no problems. The hardest parts were removing the viscous fan ( I have a fan spanner but had to make a tool to hold the pulley) and taking the plug off the back of the alternator, ended up compressing the little latch with one hand and using a long handled screwdriver to push the plug out with the other hand as couldn't do both at the same time with one hand, and there's no room for 2!

Cheers
Andy

Im glad you think that's not hard. To me anything that requires special tools to made or bought and where you have to be a contortionist to get to the part qualifies as hard to me

This is something to do if you have some spare time and some skill and patience. It's not something you just pop out in the garage to fix before dinner. Granted it is not in the same league as changing a timing belt or installing a long range tank.

Ean Austral · 28th June 2015, 08:22 PM

This is the cable that runs from the battery to the starter motor then it runs to the alternator, there is no fuse in line so if the alternator shorts it goes straight back to the battery. The eye you see is bolted onto the starter, which I have unbolted off both the starter and the Alternator and its what you see hanging down.

So I have cut off the short piece that goes to the Alternator and will run a separate cable which I will fuse so if the Alternator shorts it should blow the fuse and save the battery.

I got this idea off another thread which Graeme posted what he has done and the reason why this happens, its a fault direct from the production line.

Cheers Ean

**Wasa57** · 28th June 2015, 08:40 PM

Originally Posted by Ean Austral

This is the cable that runs from the battery to the starter motor then it runs to the alternator, there is no fuse in line so if the alternator shorts it goes straight back to the battery. The eye you see is bolted onto the starter, which I have unbolted off both the starter and the Alternator and its what you see hanging down.

So I have cut off the short piece that goes to the Alternator and will run a separate cable which I will fuse so if the Alternator shorts it should blow the fuse and save the battery.

I got this idea off another thread which Graeme posted what he has done and the reason why this happens, its a fault direct from the production line.

Cheers Ean

This solution sounds so simple - as in "why hasn't anyone come up with it before" (someone like the vehicl's designers?)
What size fuse? Please let us know how it all goes, good stuff.

Ean Austral · 28th June 2015, 08:49 PM

Originally Posted by Wasa57

This solution sounds so simple - as in "why hasn't anyone come up with it before" (someone like the vehicl's designers?)
What size fuse? Please let us know how it all goes, good stuff.

There is another thread about the same thing happening to another D3 and Graeme ( another member on the forum ) posted the reason why it happens, and in that thread he posts of the fix he done to his car. It seems like its a matter of when , not if its going to happen.

I am just following his idea, but am happy to post up how it goes. I have only today taken the cable off the starter and alternator and cut the short piece off. I put the cable back on the starter and tomorrow will make up the cable from the Alternator to the battery. I purchased a 175 amp fuse and will start with that as from what I have read the D3 alternator is 150 amp.

I will take some pics and post it up once I have it all fitted.

Cheers Ean

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