I was about to send my alternator off to Pirkle to be restored ( http://www.johnpirkle.com ) but there is currently a 6 week turn-a-round. Don't have time to wait that long so I thought I'd give it a good cleaning for right now. It works just fine but looks bad. I've tried Greased Lightning and Marine Clean but nothing works. Can someone recommend a product to clean the housing to make the aluminum look new again? How difficult is it to disassemble it so the housing can be soaked? There's only four bolts plus the pulley nut holding it together but I've heard it takes a special tool to keep the brushes from falling out during disassembly. Any one have experience doing this?

"Rough cast" mag wheel cleaner from Eagle One will do the trick. Do not let it dry on the parts or it will leave streaks.

The brushes are no big deal. You do need a special tool to reasemble the alternator and hold the brushes out while you put the thing together. I will sell you one for $6.95 plus postage or make one yourself by just straightening out a paper clip. ;)

To reasemble, you put the paper clip in a tiny hole in the brush holder while you install the rotor and then screw the housing together. Then you pull the paper clip out and the brushes will snap down on to the rotor shaft. Then you are done.

The hardest part for you might be getting the pulley nut off the main shaft. That can be tricky if you do not have the right allen wrench or an air gun with an appropriate socket on the end. If you have the air gun, you can put your sneakered foot on the fan/pulley while you hit the nut with the air gun and it will come off easily. The allen wrench mounted in a vise while you wrench down hard on the nut method is second choice for me. Ask if you need better instructions.

Or send it to Pirkle and get a perfect alternator back. :cool:

-Mark.

Larry,
What we have been doing is taking the alternator (or generator) to a local auto electric shop and have them take it apart. Then we glass bead the case etc and take it back to them to reassemble with whatever new parts are needed. We have a real good local shop that understands what we are trying to do and keeps the parts clean while he is reassembling and testing.
Hope this helps,

Have you tried Naval Jelly by Permatex, it works wonders

Don't screw around. John Pirkle for sure.

Wacky

If you have a air compressor use a impact wrench and a 15/16's socket. Hold the fan with a rag and give the impact a quick squeeze and it will take the nut off. Then take the pulley, fan and a spacer off. Take out the 4 bolts with I think a 5'16's socket and it will come apart. The only semi tricky part when putting it back together is the brushes but if you look you will see a hole in the back of the alternator that the paperclip goes through and you will see the holes where the brushes are that the clip slides into to hold the brushes. Also remember when you put it back together the position the two halves where they were before so the wiring will be in the right position. When you get the armature out you can also take off the nuts on that hold the wires for the windings and remove it also. Just make notes of how it comes apart and you should be able to get it back together. Check the bearings also. I think stores like Autozone sell rebuild kits. You can bead blast the housing and then wash it in warn soapy water while scrubbing it with a scotchbrite pad and it will look pretty good. Still will not be as nice as Pirkle with the nice painted diodes but it will be presentable.

" You can bead blast the housing and then wash it in warn soapy water while scrubbing it with a scotchbrite pad and it will look pretty good. Still will not be as nice as Pirkle ........" after beadblast cleaning find.........
SOMEBODY in or around Indy must have a vibratory or tumbler set up with CERAMIIC stones for cleaning and deburring.....this is how big time rebuild shops get there aluminum die castings looking FOUNDRY new.......Chuck S

I found a local well-known auto electric shop here in Indy (John's Auto Electric) that charges $28 plus any parts needed to go through it, clean the housing, and reassemble. If I can't get the pulley nut off myself then I'm going this route. I don't mind paying the big bucks for Pirkle but don't want to have my car parked the next six weeks waiting for an alternator. The show season is getting ready to start. Thanks everyone.

Take it to a gas station that changes tires or a tire shop and ask them to loosen the nut. Both of those will have a impact. Or go buy a electric impact wrench if you don't have a compressor.