Hi David,

Must be nice on Whidbey Island! I'll guess this is your 1983 Volvo 240?

Almost moved to Bellingham in July 2013. Had a Ferndale rental residence. Spokane is evil.

The Bosch AL57X is a 70-AMP alternator. The alternator you have now is maybe the 80-AMP model. You will need remove the pulley from your current alternator and install it on the shaft of the new alternator. The new alternator does not include the pulley. A Bosch reman may include the pulley. Unsure.

You may need a special socket or tool to remove / replace the pulley from the alternator. Though this board abounds with remove / replacement methods.

https://www.ipdusa.com/products/10889/124384-alternator-80-amp-240-740-940

The extra ten amps of (maybe) your current and later 240, 700, 940 won't hurt. A good battery provides load and will charge a little faster with the extra ten amps. Yet as you like.

As for your current alternator ...

One regulator brush is merely worn far further than the other. The shorter brush barely makes contact with the (darker) slip ring. Why the dash head lights are on after the engine starts.



The slips rings appear fine, yet I'll defer judgement to our Art B and others. Some may suggest using a ultra fine emery cloth or, better, pencil rubber eraser to brighten and polish the surface to enhance the new brush tips to seat or wear in with the slip ring surface.



These brushes are Bosch part number 11011 and are around 7$-12$ or so for the set.



With a soldering iron, you merely replace the brushes. You Tube and other resources contain instruction on voltage regulator brush carrier brush replacement.

For extra insurance and peace of mind, you can replace the entire Bosch voltage regulator / brush carrier complete. around 27$-37$+ or so.



https://www.ipdusa.com/products/6911/103064-voltage-regulator-brush-pack

Or the entire alternator with a Bosch branded NEW or reman. Say no to the AutoZone and such rabble remans.

Though as you mention the alternator has been replaced, you will want to mention the Bosch alternator model, if the label is on the housing. A part number may be stamped on the housing. I'm unsure, yet the 240 alternator change from a 55-AMP, and then a 70?, to a 80-AMP alternator on the 1984-86 model year, so, though Art, again, would give you the correct guidance.

If you could find an import auto repair or auto electrical repair service shop near you, that is honest, they can replace the brushes with new Bosch brushes in the voltage regulator / brush carrier. They can test the coils, bearings, slip rings, and AC to DC rectifier diodes.

You could keep the old alternator as a ready to go spare you may need on Whidbey Island with you in 15 years or so!

The BrickPix instructions need updating. Your only limit on uploading images to BrickPix is a image file size no larger than one megabyte. No image pixel size restriction.

Use Art's instructions here to post. Use the full image URL and not the relative URL BrickPix serves up.


Instead of the relative URL BrickPix serves up (your alternator slip ring image):
/GALLERY/images/12665.jpg

Use the full URL (same image):
https://www.brickboard.com/GALLERY/images/12665.jpg

Questions?

Hope that helps.

Thank you,

Bruce.
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