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Alternator ground problem- Ground Stud Broken...

8.7K views 9 replies 4 participants last post by  3KGT-VR4-93  
#1 ·
TLDR backstory:
So today after celebrating xmas at my folks I heard a clanking noise under my car going down the highway. Thought nothing about it untill I saw lights started to gett dimmer. So checked voltage at the LCDBC and sure enough it started dropping. Was at 10 volt when I checked and it dropped all the way to 8.5. Barely got home and in the garage...

Problem:
Checked the alternator and to my suprise the stud for the ground had broken off! Not sure what caused this. And most importantly how to fix it? Welding a turned bolt to the stud that is left there?
 

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#3 ·
I think that's the "B" (as in battery) terminal. It's not ground, it's the output of the alternator. There should also be an insulator on there. Whatever you do, DON"T GROUND IT!!
That looks burnt to me, rather than broken. The connection probably came loose and caused the terminal to burn away. Check the wire that goes on there to see if that's burnt as well.
I'm not sure how to fix it other that taking it apart and trying to replace the stud (it's part of the rectifier assembly). With the insulator in place I don't think there'll be enough threads to screw anything onto it.

Might be easiest to get another alternator.

Good luck!
 
#4 · (Edited)
Yes. Thank you for the responses. It does look burned off actually.

Didn't Think it was possible for a m6 stud to burn off like that :)

probably right also in the the connection came loose. I'll take the alternator off and take a look at it. If it's possible to save it.

So this is the stud. Not sure if I could replace only that. Guessing other stuff melted aswell with that heat. Rectifier assebly is cheap. But my alternator is 23 years old anyways so maybe I should get a new one anyways.
 

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#7 ·
okay so I took apart the alternator and replaced the rectifier assebly with a new one. But now there is a problem... I'm missing the little plastic insulator part. It bounced away under the car along with the broken stud ofcourse.

So where can I get ahold of this part or simular that does the same job? Seems like a simple part. Just special plastic material that can withstand heat so any plastic washer wont work.

In retrospec I should have just bought a used or new alternator... too much hastle for just saving 140$....

But now I did it so I just need this washer now :(
 

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