Hi I have a 1986 E 150 300ci 6cyl engine. I needed to replace the alternator and bought a new Napa alternator. That alternator lasted about 5 months before it started to fail. The dash gauge would start to flicker and sometimes swing to the left to discharge then back to charge again. It had a warranty so I got another and after about 3 months the same thing happened.
What's out there on the market that is a reliable alternator? I try and stay away from remanufactured one's but Napa has been the only alternator I found that sold as "new". All others for that year van are reman. Anyone have any experience with Wilson alternators? I've heard they are a good brand but the only one I can find for my van is a reman. one.

 

Hello, raye321! This may not benefit you, since you have already replaced the original unit, but I have had good success with taking a non-working [original] alternator [or starter motor for that matter] to a local alternator/starter repair shop. Most areas have one. In my case, the two gentlemen have been doing this for decades and service all the local farmers with old tractors, stationary generators, etc. Not too long ago, I carried in the original alternator for my 1986 F150 4.9L six to be rebuilt [zero output]. They were busy and it would have been 2-3 days, but they offered to swap mine [60A] with one they had which had already been rebuilt and was available. I did that and to my pleasant surprise, the one on the shelf was a 75A unit! The total cost was $65.

 

I would do what the previous member mentioned. But, if not possible, have you thought about rebuilding yours yourself? There is a great vid on youtube about the process. If you do a search for rebuild a ford 3g alternator, you'll find it.

I too had problems with rebuilt units. To keep costs down, the rebuilders only replace the parts that don't work, leaving other parts that may have many miles on them. That's why you get failure not long after installation.

Good luck. Oh, you might want to ck rock auto.

 

Look for alternatorstarterrebuildkits.com or somesuch. They have kits for just about everything and videos to walk through the work. Contain voltage regulator and brushes, bearings and parts required to do a good job.

 

Yes I have thought of that as well. I used to do that years ago when there were not so many auto parts stores around. There is a repair shop here and has been around for many years. I think I will give them a call. I was reading exactly what is done to a remanufactured alternator and you are right, they only replace whatever is wrong at the time. No wander they dont hold up.

 

It's really kind of a package deal, the whole battery, charging and start system to include cables, voltage regulator, solenoid, and esp. good clean tight solid grounds. Not just the brand.

Any resistance in the circuit means the battery isn't being fully charged, slower cranking, and more stress on the alternator. The voltage regulator pegs out to the high side and constantly boils the electrolyte to try and keep up. That's why you see all the corrosion buildup around the battery terminals. So it gets even worse.

A well tuned engine in turn, only needs a split second on the starter to fire off. When you hear people grinding and grinding on the starter to light an out of tune engine, it's a safe bet that the starter and solenoid is not long for this world. If it does finally start, then it's the alternator's turn again to be wrung out trying to charge the battery back up through corroded cables and connections.

When the starter is smoked, it becomes a permanent ampere hog, dragging the now already depleted, sulfated battery down even further, but now the spark at the plugs is attenuated just at that very instant it needs the maximum juice to get the engine to fire. Rinse lather repeat.

 

If you buy one online, the are only about $80. Compare that to $60 with shipping to rebuild it yourself. Not much to an alternator, but that is also why there isn't much difference in normal amp alternators.