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Alternator 504338098R

Problem: Dead battery due to alternator not charging.

Solution Date: In Review- final solution not found

Failure Mode:

    • Alternator not charging

Root Cause:

      • Brush wire gets frayed if the brush is allowed to extend beyond its original position.
      • Wire becomes frayed until remaining brush wire is unable to support the normal operating condition resulting in higher resistance and ultimately no output of the alternator.
      • Found when the operator removed the protective cap the brushes would fully extend causing they fray in the wires.


  • Updated Process Standards: Our supplier has revised their handling processes for regulators during assembly, ensuring each unit is supported correctly to prevent any undue stress on components
  • Thermal Management Improvements: To combat the high heat conditions associated with 200A operation, we’ve started applying thermal grease to the rectifier heat sink. This change aims to reduce the temperature by 23-30°C, significantly extending the diode’s lifespan and overall unit reliability.
    84246892R Product improvement examples

    If you have questions about this or our Reman products, please contact the Reman Technical Center at (888) WHY-REMAN or

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