DIY - Flickering Battery Light
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Fleet Owner
Joined: Apr 2008
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From: 0,0,1
DIY - Flickering Battery Light
So the other day in my 01 Navigator my battery light starts mildly flickering, almost like a shimmer. I tested the battery which passed all tests as good. The alternator was putting out 13.8 volts at idle with the A/C and headlights on. When I'd reved the engine the light would go out, but it would start the flickering as the RPMs came back down. I also checked for loose connections and found none. The belt and tensioner are new. So the battery, the alternator, belt, tensioner, and the connections were all good. This is my life, I always seem to get the problems that would stump just about anybody. 
I was however convinced the problem was with the alternator since engine RPMs affected the battery light. I took the alternator off and disassembled it. I lightly touched the brushes to my wire wheel, then did the same to the commuter rings on the armature. For the rings I applied just enough pressure to clean them and make them shiny, but not enough to create grooves, scratches, or remove any material. I reassembled everything, fired the engine up and the battery light hasn't come on yet. Yet another $150.00 saved, so I'm happy!
I was however convinced the problem was with the alternator since engine RPMs affected the battery light. I took the alternator off and disassembled it. I lightly touched the brushes to my wire wheel, then did the same to the commuter rings on the armature. For the rings I applied just enough pressure to clean them and make them shiny, but not enough to create grooves, scratches, or remove any material. I reassembled everything, fired the engine up and the battery light hasn't come on yet. Yet another $150.00 saved, so I'm happy!
Postmaster
Joined: Jan 2009
Posts: 4,584
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From: Chesapeake, Va.
Is the bulb still good? 
Just picking on you alloro, I had a similar problem and it turned out that the armature had deep gooves worn into it. I thought it was worn out brushes or a dying regulator. The new brushes only came with a new regulator so when I got it apart I was shocked to find really deep grooves worn in so I was forced to buy a new alternator. It was the worst I had ever seen, well below safe turning diameter.
Glad the job turned out good for you.
Just picking on you alloro, I had a similar problem and it turned out that the armature had deep gooves worn into it. I thought it was worn out brushes or a dying regulator. The new brushes only came with a new regulator so when I got it apart I was shocked to find really deep grooves worn in so I was forced to buy a new alternator. It was the worst I had ever seen, well below safe turning diameter.
Glad the job turned out good for you.
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Fleet Owner
Joined: Apr 2008
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Better men have tried and failed. 
You can buy rebuild kits that come with a new pair of bearings and a new set of slip rings for about $21-$22 over on eBay. Then there are other kits that for another $10 or so will come with a new set brushes.
The point of my original post was to let people know that it's not always necessary to dump $150+ on another alternator when you can repair your existing one. Starters too, but that's a post for another day!
The point of my original post was to let people know that it's not always necessary to dump $150+ on another alternator when you can repair your existing one. Starters too, but that's a post for another day!
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Fleet Owner
Joined: Apr 2008
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And it's not really that difficult either. The worse part about repairing them is getting the rebuild kits, since auto parts store tend not to carry them. I guess they'd rather sell you the more expensive whole replacement alternator/starter.
Postmaster
Joined: Jan 2009
Posts: 4,584
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From: Chesapeake, Va.
They only consider their bottom line. Not the consumer.
Post Fiend
Joined: Feb 2008
Posts: 10,977
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From: Lancaster, Pa.
Funny you mention this Alloro, my wifes Expy's Alt. gave up the ghost yesterday, killed the 8 year plus battery for good now. I'd give it a shot opening it up but I'm taking it over to a local rebuilder here, I'm sure its easy but I would never hear the end of it. Signed, Tim the tool man...
Good job on the fix...
Good job on the fix...
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Tuned
Joined: Dec 2006
Posts: 344
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From: huntsville, alabama
Great fix. The past 2 weeks there have been several alternator posts on the forum. Must be the heat! Glad you got it fixed.
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