Alternator Regulator/Brush Reliability. [Inquiry] Is it wise to preventatively change out a 10 yrs old voltage regulator now?
[Response: Gary DeFrancesco] The regulators themselves are fairly robust. It is the attached carbon brushes that wear out. If let go too far, the bushes become ineffective and the alternator stops charging eventually. I would pull the regulator/brush assembly out and have a look at it. If the brushes are less than about 3/16″, I would go ahead and replace the assembly. An aftermarket assembly costs about $20. A Bosch unit runs about $50. I have installed both in my 2 745Ts this year. So far both are working fine. My gut feel is the Bosch assembly is going to last longer, but time will tell. I know there are those who say the brushes can be replaced and the regulator reused. If you have the tools and want to spend the time, go ahead. However, I do not know how much longer the electronics in the regulator will last. With all the heat under the hood, the electronics will eventually fail. Will they last through a second set of brushes, I don’t know. So I just bypassed the question and put