I'd put the brush/regulator replacement fourth on my list, but only 'cause it's $$$.
First, clean 'n retension (= bend) all the fuse clips. A loose or tarnished fuse clip (don't remember which on) can cause weird stuff like this. Anyway, it's good preventive maintenance.
Second, examine the wiring around the alternator, looking carefully for crumbling insulation. If you see it, then the insulation may also be crumbling in the harness where it loops under the front engine pulley. You can usually repair the failing wires with good results. Also, thoroughly insulate and protect the harness where it goes under the metal clips near the pulley. These clips can cut through the insulation, and your car goes up in serious flames.
Third, start thinking about new brushes. If you can find replacement brushes, then try those -- they're only a coupla bucks, vs. all the money for the regulator. Your regulator is probably fine. Of course, you must solder the new brushes into the regulator assembly, which might deter you.
Finally, new regulator assembly. Plug 'n play.
--
Don Foster (near Cape Cod, MA)
|