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Car Forum / Driving, Maintenance, Tuning / Maintenance and Repair / October 2007

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Chunk of "something" in the alternator?

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MasterBlaster - 14 Oct 2007 23:38 GMT
We were in the midst of doing a quickie alternator change the other day, had pulled the new one out of the box, and were getting
ready to swap the fan over, when I heard a rattle from inside the new one. I turned it over a couple of times, and could see though
the holes in the case what looked like a small pebble. It was too big to just fall out, so I pulled the regulator/brush holder and
shook it out through that hole. I didn't feel like pulling the new alt all the way apart to look inside, as it was right at the end
of the day, plus I didn't want to possibly mess up anything that might jeopardize a "warranty return".

The piece is triangular, like a slice of pie. Maybe 3/4" long, 1/2" wide, 1/4" thick. Very hard, possibly ceramic. Almost white, but
with a greyish tinge and flecks of darker mixed in. Top and bottom surfaces are flat, the two long sides are curved slightly
inwards, as if someone had pinched it with their fingers, but very symmetrical. The sides are also sloped a bit, making the top
surface smaller than the bottom. All edges are rounded, and all surfaces are shiny, as if it's been put through one of those old
"rock polisher" things. No markings, logos, holes, indentations, or glue residue. Nothing to suggest whether it belongs in there, or
got dropped in during assembly. Very strange.
Steve - 15 Oct 2007 16:34 GMT
> All edges are rounded, and all surfaces are shiny, as if it's been put through one of those old
> "rock polisher" things.

You hit closer than you ralize. That sounds very much like a piece of
abrasive from one of the vibrating polisher vats that cheap-a.s
"remanufacturers" run all the core alternator, starter, and water pump
cases through to clean them up prior to reassembly. Who knows what else
wouldn't pass a kindergarten QA test in that "remanufactured" alternator?
Steve - 15 Oct 2007 16:38 GMT
>> All edges are rounded, and all surfaces are shiny, as if it's been put
>> through one of those old
[quoted text clipped - 5 lines]
> cases through to clean them up prior to reassembly. Who knows what else
> wouldn't pass a kindergarten QA test in that "remanufactured" alternator?

Check this site, a few pages down under "ceramic media," to see some
drawings of the shapes of abrasive media chunks that I'm talking about:

http://www.metalfinishingsystems.com/tt-massfinishing.html
MasterBlaster - 15 Oct 2007 19:04 GMT
> >> All edges are rounded, and all surfaces are shiny, as if it's been put
> >> through one of those old
[quoted text clipped - 10 lines]
>
> http://www.metalfinishingsystems.com/tt-massfinishing.html

Woo-hoo! I think we may have a winner.

I followed your clue, and let Google Images lead me farther, and found... http://www.abrasiveproducts.com/tumbling_vibratory_media/

3rd line down in the middle, but a bit more like his blue buddy to the left,
with 2 equal sides and 1 slightly shorter. Just variations on a theme?

Maybe the rebuilders left it there on purpose, because they knew we'd find
it, and could use it to repolish the slip rings when they get a little worn a few
years down the road. Yeah, that must be it. Uh-huh. Right. Sure.
 
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