Disco 3 Alternator rebuild, parts list





Page 1 of 3 1 2 3 LastLast
Results 1 to 20 of 59
  1. #1
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Disco 3 Alternator rebuild, parts list

    Just been through this exercise so thought I'd post the list of components you need, this was on a V8 but I'm sure the TDV6 would be similar. Unfortunately I didn't take any photos but it really is quite straight forward.

    I replaced the following:
    Diode pack (purchased from GT40 on this forum)
    Bearings 47od, 17id and 14 thick (this is the one closest to the pully and takes most of the punishment).
    The other one is 35od, 15id and 13 thick. This one was harder to find as it's non standard but bearing man had both. His one is also MUCH more difficult to remove so if yours feels fine just leave it alone!
    Brush box, picked one up from my local Midas, it's the same as a Toyota quantum, R100.

    Altogether the parts cost about R800.

    There are guides online about how to remove and dismantle the unit but nothing on the bearing sizes or brushes. It took me longer to find the parts than to do the job. So I hope this saves someone some time.

    I also changed all the tensioner and idler bearings at the same time they are all standard 6203 and take 10 mins each if you have a vise a hammer and a socket set.

  2. The Following 2 Users Say Thank You to Hanny For This Useful Post:


  3. #2
    Join Date
    Aug 2015
    Location
    Cape Town
    Age
    54
    Posts
    854
    Thanked: 257

    Default Re: Disco 3 Alternator rebuild, parts list

    Thanks for the post

  4. #3
    Join Date
    May 2014
    Location
    Kenridge
    Age
    71
    Posts
    537
    Thanked: 90

    Default Re: Disco 3 Alternator rebuild, parts list

    Many thks Hanny - great stuff!!
    2005 Disco 3 TDV6


  5. #4
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Re: Disco 3 Alternator rebuild, parts list

    Thanks guys, I get so much good info off this site I thought I'd try and do my bit

  6. #5
    Join Date
    Nov 2013
    Location
    Stellenbosch
    Age
    61
    Posts
    816
    Thanked: 15

    Default Re: Disco 3 Alternator rebuild, parts list

    Great info - thanks Hanny!
    Regards.
    2008 Discovery 3 V8 HSE
    2015 Bushlapa Miskruier 395 (...hy het nie naam nie, sy naam moet hy nog kry....)
    Previous: 2000 Discovery 2 TD5 SE, XT 140

  7. #6
    Join Date
    Nov 2013
    Location
    Stellenbosch
    Age
    61
    Posts
    816
    Thanked: 15

    Default Re: Disco 3 Alternator rebuild, parts list

    One more question Hanny. How did you join the diode pack to the winding wires? Normal solder or other process?
    2008 Discovery 3 V8 HSE
    2015 Bushlapa Miskruier 395 (...hy het nie naam nie, sy naam moet hy nog kry....)
    Previous: 2000 Discovery 2 TD5 SE, XT 140

  8. #7
    Join Date
    Oct 2010
    Location
    Centurion
    Age
    35
    Posts
    5,689
    Thanked: 39

    Default Re: Disco 3 Alternator rebuild, parts list

    You can solder it normally. I did that when I replaced the diode pack.

    Discovery 3 V8 SE
    Self designed Rock and Tree Sliders.
    Next: Project Bashplate
    1981 Series 3 S R6 88" Allmost Perfectly Restored

  9. #8
    Join Date
    Feb 2012
    Location
    Brackenfell
    Age
    46
    Posts
    447
    Thanked: 44

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by Hanny View Post
    Thanks guys, I get so much good info off this site I thought I'd try and do my bit
    Hi Hanny,
    what were the signs of the Alti going .. .. Sounds like you got it in 'time' OR was it a full recovery repair?


    cheers
    JC
    2009 Range Rover Sport 4.4 V8 HSE (his)
    Izmir Blue

    2012 Audi S3 (hers)
    Brilliant Red

  10. #9
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Re: Disco 3 Alternator rebuild, parts list

    Carel like SS said you can use normal solder (at least I did). You will need an iron with quite a bit of juice. I had to resort to heating up a spare tip with a blow torch! Oh and i couldnt melt the original solder, had to cut it off.

    Jacques from one morning to the next it started making a buzzing sound that was rev dependant. I took the fan off (made a tool out of two steel brackets that i hammered straight and bolted together like scissors, then drilled a hole in each in the right place to allow me to bolt it to the fan bracket) and used a stethoscope to pin point the noise to the alty.
    I initially thought it was bearings, when i opened it up a couple of the diodes looked less than 100%. It was only when assembling that i noticed the brushes were barley pushing against the shaft.

  11. #10
    Join Date
    Oct 2010
    Location
    Centurion
    Age
    35
    Posts
    5,689
    Thanked: 39

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by Hanny View Post
    Carel like SS said you can use normal solder (at least I did). You will need an iron with quite a bit of juice. I had to resort to heating up a spare tip with a blow torch! Oh and i couldnt melt the original solder, had to cut it off.

    Jacques from one morning to the next it started making a buzzing sound that was rev dependant. I took the fan off (made a tool out of two steel brackets that i hammered straight and bolted together like scissors, then drilled a hole in each in the right place to allow me to bolt it to the fan bracket) and used a stethoscope to pin point the noise to the alty.
    I initially thought it was bearings, when i opened it up a couple of the diodes looked less than 100%. It was only when assembling that i noticed the brushes were barley pushing against the shaft.


    Mine did exactly the same, also a high pitched noise also rev dependent. It took me a while to figure out it was the alternator, but not the bearings on the alternator.


    You are the second person that I have heard about that alternator whine, and also on the V8, I wonder if any diesel guys' alternators have done the same?

    Discovery 3 V8 SE
    Self designed Rock and Tree Sliders.
    Next: Project Bashplate
    1981 Series 3 S R6 88" Allmost Perfectly Restored

  12. #11
    Join Date
    Oct 2010
    Location
    Centurion
    Age
    35
    Posts
    5,689
    Thanked: 39

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by JacquesC View Post
    Hi Hanny,
    what were the signs of the Alti going .. .. Sounds like you got it in 'time' OR was it a full recovery repair?


    cheers
    JC


    In my case there were no warnings on the dash, it was just the whining noise.

    Discovery 3 V8 SE
    Self designed Rock and Tree Sliders.
    Next: Project Bashplate
    1981 Series 3 S R6 88" Allmost Perfectly Restored

  13. #12
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by Silver Shadow View Post
    Mine did exactly the same, also a high pitched noise also rev dependent. It took me a while to figure out it was the alternator, but not the bearings on the alternator.


    You are the second person that I have heard about that alternator whine, and also on the V8, I wonder if any diesel guys' alternators have done the same?
    I have my doubts about it being the bearings in mine as the idlers were much worse but were not the cause of the noise (i know this because I changed them first and replaced the belt to check)

    I also found a few posts on other sites linking a buzzing sound to the diode pack.

    As far as I know the diesel has a very similar (if not identical) unit.
    Last edited by Hanny; 2016/05/13 at 09:27 AM. Reason: update

  14. #13
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by JacquesC View Post
    Hi Hanny,
    what were the signs of the Alti going .. .. Sounds like you got it in 'time' OR was it a full recovery repair?


    cheers
    JC
    The alty was still charging so no warning apart from the noise.

  15. #14
    Join Date
    Nov 2013
    Location
    Stellenbosch
    Age
    61
    Posts
    816
    Thanked: 15

    Default Re: Disco 3 Alternator rebuild, parts list

    Thanks Hanny and SS.

    Mine whined very loud, no dash light on and did not charge at all. I still wonder how the diode pack was joined to the windings. It looks as if mine was "welded with copper". Also could not melt it with a soldering gun.

    Still need to rebuild mine with the leads on the diode pack that Georgecape and Hanny gave me.

    Here are some pict's. One can clearly see the popped diodes.

    Regards.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	IMG_20150329_135936.jpg 
Views:	265 
Size:	49.7 KB 
ID:	402622   Click image for larger version. 

Name:	IMG_20150329_140028.jpg 
Views:	246 
Size:	68.5 KB 
ID:	402623   Click image for larger version. 

Name:	IMG_20150329_135427.jpg 
Views:	249 
Size:	71.0 KB 
ID:	402624  
    2008 Discovery 3 V8 HSE
    2015 Bushlapa Miskruier 395 (...hy het nie naam nie, sy naam moet hy nog kry....)
    Previous: 2000 Discovery 2 TD5 SE, XT 140

  16. #15
    Join Date
    Jul 2015
    Location
    Cape Town
    Age
    48
    Posts
    497
    Thanked: 36

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by Carel Kriek View Post
    Thanks Hanny and SS.

    Mine whined very loud, no dash light on and did not charge at all. I still wonder how the diode pack was joined to the windings. It looks as if mine was "welded with copper". Also could not melt it with a soldering gun.

    Still need to rebuild mine with the leads on the diode pack that Georgecape and Hanny gave me.

    Here are some pict's. One can clearly see the popped diodes.

    Regards.
    WOW my diodes looked new compared to those ones

  17. #16
    Join Date
    Feb 2009
    Location
    Pretoria
    Age
    46
    Posts
    550
    Thanked: 107

    Default Re: Disco 3 Alternator rebuild, parts list

    Thought the whining was the alternator giving notice as I had replaced all the idler /tensioner bearings in Dec. So had the Alternator in the back of my mind. One morning April in Kruger the batt light refused to go out. Turned out the Alternator died between the previous evening and then, I had a new one couriered in . Took a few mins to fit so the spare is still here to recon.


    funny thing is, the whining noise is still there....
    Wynand
    2005 Discovery 3 HSE v8
    2002 Discovery II XS v8 (sold)
    1974 Chev K 25 (julle dink 'n v8 is dors)
    Land Rover - making mechanics from motorists since 1947 and electronic engineers since 1989!

  18. #17
    Join Date
    Feb 2012
    Location
    Brackenfell
    Age
    46
    Posts
    447
    Thanked: 44

    Default Re: Disco 3 Alternator rebuild, parts list

    Quote Originally Posted by Hanny View Post
    Just been through this exercise so thought I'd post the list of components you need, this was on a V8 but I'm sure the TDV6 would be similar. Unfortunately I didn't take any photos but it really is quite straight forward.

    I replaced the following:
    Diode pack (purchased from GT40 on this forum)
    Bearings 47od, 17id and 14 thick (this is the one closest to the pully and takes most of the punishment).
    The other one is 35od, 15id and 13 thick. This one was harder to find as it's non standard but bearing man had both. His one is also MUCH more difficult to remove so if yours feels fine just leave it alone!
    Brush box, picked one up from my local Midas, it's the same as a Toyota quantum, R100.

    Altogether the parts cost about R800.

    There are guides online about how to remove and dismantle the unit but nothing on the bearing sizes or brushes. It took me longer to find the parts than to do the job. So I hope this saves someone some time.

    I also changed all the tensioner and idler bearings at the same time they are all standard 6203 and take 10 mins each if you have a vise a hammer and a socket set.
    Hi Hanny,
    do you perhaps have the part numbers for those bearings that you bought for the Alti . . .
    I might have a potential issue
    2009 Range Rover Sport 4.4 V8 HSE (his)
    Izmir Blue

    2012 Audi S3 (hers)
    Brilliant Red

  19. #18
    Join Date
    Jan 2013
    Location
    Stellenbosch
    Age
    58
    Posts
    451
    Thanked: 8

    Default Re: Disco 3 Alternator rebuild, parts list

    Had my D3 V8 alternator rebuilt by an Auto electrician recently due to a buzzing noise. He said he replaces the standard 40 amp diodes with 80 amp Bosch diodes which he apparently presses into the pack. Any comments on this as to advisability etc? He gave me a 1 year warranty on the job.
    2007 Disco 3 V8 s

  20. #19
    Join Date
    Jan 2014
    Location
    Benoni
    Age
    43
    Posts
    828
    Thanked: 52

    Default Re: Disco 3 Alternator rebuild, parts list

    Cannot go wrong with more capacity on the diodes.

    The alternator only passes so much current, the 80A is overkill but will mean the diodes aren't working hard at all, resulting in a longer lifespan.

    What you want to watch out for are the quality of the diodes he put in, Bosch is great quality so no worries there, and if the physical size has changed, with any potential resultant rubbing against other parts if the form factor is larger.
    Last edited by nitrious; 2016/07/25 at 10:29 AM.

  21. #20
    Join Date
    Feb 2012
    Location
    Brackenfell
    Age
    46
    Posts
    447
    Thanked: 44

    Default Re: Disco 3 Alternator rebuild, parts list

    the bearing details & costs
    Attached Images Attached Images
    2009 Range Rover Sport 4.4 V8 HSE (his)
    Izmir Blue

    2012 Audi S3 (hers)
    Brilliant Red

Page 1 of 3 1 2 3 LastLast

Similar Threads

  1. Disco 1 parts needed please have a look for us
    By Garreth G in forum Land Rover
    Replies: 8
    Last Post: 2015/11/23, 02:15 PM
  2. Disco 4 XS
    By pwgg in forum Land Rover
    Replies: 75
    Last Post: 2013/08/12, 01:50 PM
  3. 2007 disco 3 HSE vs 2008 disco 3 S
    By Marco in forum Land Rover
    Replies: 15
    Last Post: 2012/11/19, 09:59 PM
  4. Parts list and numbers - website
    By NewLandy in forum Land Rover
    Replies: 2
    Last Post: 2012/08/27, 05:39 PM
  5. Japanese vehicle parts availability
    By Fabfender in forum General 4x4 Discussion
    Replies: 0
    Last Post: 2011/04/11, 03:22 PM

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •