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Done! The alternator has been reinstalled and adjusted to 28V output per the TM! [emoji1360] Sent from my iPhone using Tapatalk

New brushes installed. Encapsulated Holders/wires/capacitor in silicone to ease replacement in the future if needed. Sent from my iPhone using Tapatalk

Slip rings polished up with 400 grit Sent from my iPhone using Tapatalk

Brush holder released from it’s epoxy cocoon. A pencil tip soldering iron worked great in this case. Sent from my iPhone using Tapatalk

Voltage regulator adjustment plug was stripped/frozen. Drilled and extracted so the VR can be adjusted in the future. 10M Tapered plug replacement Sent from my iPhone using Tapatalk

Brushes are on the way [emoji106] Sent from my iPhone using Tapatalk

Found TM 9-2920-225-34 :) Looks like two choices from what I can gather: 1) de solder the rectifier to stator leads and remove rectifier housing 2) remove epoxy vibration potting from yellow capacitor/brush housing to remove brush housing from rectifier

Voltage regulator and rectifier cleaned in preparation for service. Sent from my iPhone using Tapatalk

Ok, progress. Removal and disassembly confirms worn brushes. One bush is entirely disconnected from the lead. Ordering a brush kit to repair. Voltage regulator looks good visually. Q: How are the brushes replaced? Looks like the rectifier housing needs to be separated from the main body to...

Thanks! I just happened to find Southern Automotive in the archive and called them today. I did not find their trouble shooting content but hope to speak to them directly tomorrow. Hopefully this is as simple as replacing the regulator and brushes Sent from my iPhone using Tapatalk

Editorial this silicone potting is great. A PITA to remove for access to term 568 though. Sent from my iPhone using Tapatalk

Full battery voltage at alternator side of wire 568. Voltage at wire 2A fluctuates in a low range while running. Moving to removing alternator for disassembly/inspection of voltage regulator and brushes. Q: is there a bench testing procedure to test the stator windings and other internal...

Update: Per TM 9-2320-280-20-1 Step B2 page 2-204 confirmed voltage on harness side of wire 568. Checking alternator side of wire tomorrow. Sent from my iPhone using Tapatalk

I’m using the M998A1 component testing and troubleshooting manual. However, this manual refers to the 100 amp alternator versus the 60 amp alternator. Is there any difference in triage? I’m getting no charging output. I have not yet conducted the amps test however the output voltage is battery...

3/4” mat 4’x6’ cut down. Yeah, it definitely smells like new tires. I understand it will off gas’s after a while. Sent from my iPhone using Tapatalk

Horse stall mat for the bed. Sent from my iPhone using Tapatalk

I’ve found it is fairly easy to straighten minor panel damage on the 802/803 series... Sent from my iPhone using Tapatalk

Also applied Noico black insulation to one access door and the top panel over the main wiring. Sent from my iPhone using Tapatalk

Finished making replacement output wires A2/B2/C2. Added an insulated cable clamp and abrasion shielding as well. Sent from my iPhone using Tapatalk

Replaced RR spring on M998. RR was a tad fatigued. LR is next. 1750# springs before/afterwards. New plow springs are a great deal. Sent from my iPhone using Tapatalk