Chrysler R5252539 40/90 Amp Complete

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Detach the cable from the battery and electrical connector(s) from the alternator. Loosen the alternator adjustment and mounting bolts and detach the drivebelt. Remove the adjustment and pivot bolts and separate the alternator from the engine. Take the old one with you when purchasing a replacement unit. Make sure the new/rebuilt unit looks identical to the old one. Switch the pulley if necessary. Installation is the reverse of removal. Adjust the drivebelt tension and check the charging voltage.

The alternator is operated by a drivebelt turned by the crankshaft pulley. The rotor turns inside the stator to produce an alternating current, which is then converted to direct current by diodes. The current is adjusted to battery charging needs by an electronic voltage regulator, which is controlled by the logic and power modules.

Due to the specialized training and equipment needed to test and service the alternator, it is recommended to take the vehicle to a dealer or repair shop with the proper equipment if a problem arises. The most obvious sign of a problem is the alternator warning light on the instrument panel coming on, particularly at low speeds, indicating that the alternator is not charging. Other symptoms include dim headlights and the starter motor turning the engine over slowly, indicating a low battery state-of-charge. The first check should always be the drivebelt tension, followed by ensuring all electrical connections are secure and free of dirt and corrosion. If the drivebelt tension, electrical connections, and battery are good, an internal fault in the alternator or voltage regulator is likely. Due to the specialized tools and techniques required, diagnosis and repair should be left to a properly-equipped shop. If the vehicle has considerable miles on it, a good alternative is to replace the alternator with a rebuilt unit.

To begin, remove the alternator and then take out the screws that secure the brushes and plastic holders to it. Next, remove the insulating washers and separate the brushes from the alternator end shield. For installation, follow the reverse order of the removal process.

Installation is the reverse of removal, ensuring that the wire connections are correctly made and that the drivebelt is properly tensioned.

The negative (-) cable should always be grounded, while the output (+) cable should never be grounded and should always be connected to the positive battery terminal.

If the new/rebuilt alternator does not have a pulley installed, you may have to switch the pulley from the old unit to the new/rebuilt one. When buying an alternator, find out the shop's policy regarding pulleys - some shops will perform this service free of charge.

To install the alternator, place it in position and install the pivot bolt and nut finger-tight. Install the drivebelt and then the locking/adjusting bolts, adjusting the drivebelt tension and tightening the locking bolt. Finally, tighten the pivot bolt and nut.

The only components subject to wear are the brushes and bearings. The bearings are sealed for life and the brushes should be inspected for wear after about 75,000 miles (120,000 km) and the length compared to the Specifications. Regular maintenance consists of cleaning to remove grease and dirt, checking the electrical connections for tightness and adjusting the drivebelt for proper tension.