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Every few years the alternator either stops charging or completely stops rotating. Is this a common problem or do I just get bad alternators I usually put in rebuilds. :(
You could try taking your alternator to a local alternator rebuild shop for a rebuild by a local professional that uses good quality bearings. I think Advance Auto can get you a AC Delco rebuilt alternator, the quality should be better than most over the counter rebuilds.
If it's chewing up bearings, check to see that the belt and pulley are lining up correctly. If no other accessories are showing this problem, is it possible that alt is sitting at an odd angle and causing the belt to put excess stress on the bearings? Just a thought.
Also, very possible you are getting bad rebuilds. Where are you getting the alternators? The discount houses (ie Checker, AutoZone, Pep Girls etc) take the cores they get, clean them up, replace the one part that failed, and call it a "rebuilt" alternator. They can offer a lifetime guarantee because they figure that ....
A. They know they will get a high percentage of them back, but their costs are so low that they can give you 5 or more alternators over the course of the warranty and still make money.
B. Most people who own older cars don't keep them for long, and won't bother passing the lifetime warranty on to the next owner.
The higher quality units are from Napa, CarQuest, and of course, AC Delco.....but they cost more. I went the AC Delco route on my starter simply because I didn't want to have to crawl under the car and swap a starter every 6 months.