Voltage Regulator

[reyemtm]

I have an 85 jetta with a 45 amp alt and need a new regulator - part #1197311005 but the only one I can find is for a 65-115 amp alt with part number 1197311028 - will this work? Looks the same but maybe that is meaningless. Actually I just need new brushes but have no idea how to change them out, so figured I would just replace the whole regulator.

Thanks

[Dakotakid]

Changing brushes is quite easy.
First, get one of the parts stores to order brushes for you.
When I used to get brushes, there would be two brushes in each box. And, there would be two new springs in there as well.
The last brushes I purchased only had one brush in each box and there were no new springs included. Now, you can probably get by without new springs, but new springs help to ensure a good contact with the slip ring on your alternator shaft.

So, try to find out what you are ordering. (Most part stores won't have a clue until they open the box).  

Once you obtain the new brushes, take an electrical soldering iron (gun) and quickly heat the soldered connections on the topside (as they sit in the car) of the brush guides. You will easily see these solder points. (Do one at a time on your first attempt).

As the factory solder gets molten, the sping will push the old brush free and it can fall out (removal). Be careful not to lose the little spring on the wire.

If you heated the original soldered area enough, you should now have a little hole at the top of the brush groove. This hole is where you will insert the new wire on the new brush during assembly.

Grasp the new brush, insert the brush's wire through the center of the spring and insert into the brush guide. Sometimes it is difficult to get the wire to come through the top. You may have to get the old solder molten while getting the wire out the top. Keep applying pressure to the new brush to keep it all the way into the slot.

Once you have the wire protruding through the top, get the solder in the molten state (and, maybe, add a little more solder), let it cool.......and, presto.....done!!!! Now, do the other side. Make sure the brushes freely travel in their slots.

I should add that you need to inspect the condition of the slip rings (surfaces which the brushes make contact on the alternator shaft) before going with new brushes. They can have significant grooves from many miles of motoring. If they are significantly grooved, new brushes won't last long. You may have to disassemble the alternator and have the slip rings very slightly milled in order to restore a smooth surface. The "meat" on the slip rings does not last forever.....eventually, we all die.
Right now, I have 8 Bosch regulators waiting for new brushes (just like this). I usually wait and do a bunch of them "assembly line style." If you ever get to this point......you will know you do a hell of a lot of driving!!!!!!