I am having absolutely bad luck with alternators. I attempted to purchase a replacement from the local Delco retailer for my C5 (2001) with auto transmission. It had to be ordered as it was not a stock item.

Upon arrival I opened the box and pieces of the plastic backing along with the three wire connector jack fell out of the box. It had been shipped in the shelf storage box with no other padding. I asked for another.

The second one arrived and it seems the shipper went out of the way to bust the three wire connector jack - it was demolished. Again the unit had been shipped in the raw box used for shelf storage.

I turned to the forum and ordered a used unit. It arrived packed in the same style shelf packaging box as previous two units. Sure shootin - the three wire connector was busted.

I called a couple of local shops to see if they could replace/repair the connector. Each told me the regulator/diode assembly would have to be replaced and they could not buy the replacement part needed. Referred me back to the Chevy dealer.

Chevy dealer told me the piece parts for the alternator are not available - that I have to buy the complete alternator.

So the following questions come to mind.

1 The connector has O-Rings seals. That implies to me water resistance at the connector. How critical is the integrity of this seal to proper operation.

2 Are there parts houses which offer piece parts for the C5 A4 alternator?

3 Are there rebuilders which repair C5 A4 alternators and ship with adequate packing to protect the fragile plastic parts?

Or do I just bite the bullet and pay the dealer $650.00 for a rebuilt plus the governors 8% protection money?

 

There is a "kit" that replaces the voltage regulator .... part number 12533439

http://www.gmpartshouse.com

shows they stock the part ... call Gene and ask if he can send you one to try and fix the problem.

I'd be concerned that other damage may have been done internally .... but if you want to try it out ....

Good luck.

 

Appreciate the info on the part number. I understand the worry over possible damage to the internals. The pulley showed signs of impact. However it seems to turn freely. I may mount it since the connector will still attach (just no seal for the O-Rings) and see if it operates normally. When hand spinning the alternator it does not appear to be running out of round.

Is there an online GM parts catalog for the average owner which lists parts such as the voltage regulator and diode assemblies? Even GMPARTSHOUSE shows the alternator as the minimum available assembly. I find it interesting they have the voltage regulator available in light of the note on the alternator page "Component Parts Not Serviced Separately".

Don't get me wrong, I am glad to gain access to the voltage regulator, but how is the average smuck like me to find these hidden parts without pestering those in the know over and over again?

 

Try your local auto parts store.
I have ordered connectors with a pigtail assembly to fit alternators.
If you do not want to splice the wire, you can just remove the connector and transfer it to the alternator harness.

 

Hi, the intended seals at the connectors are somewhat important for longevity,(you can bet the farm that GM, or any manufacturer in todays world wouldn't spend an extra 1/4 cent on anything it deemed not neccessary), if getting the proper connector with the seals intact is a big pita, you could always apply a bit of high temp silicone caulk carefully to seal the connector after attaching it. Just don't get any inbetween the connections. Yes a bit unorthodox, but will serve the same purpose.
Good Luck

 

Thanks for the suggestion on the silcone seal. It had crossed my mind after all the frustration with the busted plastic on three separate occasions but my **** retentive nature blocks that solution on a car like this. On a Ford Escort or Chrysler product it is ok but only under the most dire (150 miles North of Flagstaff, Arizona with temps of 105 F in a deluge in an arroyo with no cell service off of US-89) of situations on a Corvette.

 

You can download a softcopy of the GM Corvette Part Manual from this location ....

http://www.davidfarmerstuff.com/

Scroll down and you will see the OEM C5 parts file available ..... RIGHT click on that heading and a pop-up box will appear. Select the option "Save Target as ....." and another pop-up will appear allowing you to chose where you want to put the file on your computer and what to call it. Once you have downloaded the file you will need Adobe Reader to open it.

NOTE: The file is about 120 MB so if you're on a dial-up connection ... forget it ......

Also note that some part numbers have changed since the manual was issued, but often if a number has changed the old one will allow the place you are ordering from to find the new number.

 

Many thanks for the link to the part number listing.