The second-hand alternator had no oil whatsoever covering it - looks in good nick - just dusty on the outside and inside so I cleaned it up - cleaned case, regulator, rectifier (now a nice grey) and the brush box. All nice and clean inside. And here's the back case - the old oil-covered unit...

Picked-up a used and tested alternator for $75 (came off a wrecked Landy lying in a shed up in the country) - slip rings are good and no oil on it anywhere; it had two auto electrician stickers on it, so has been out and sent to the auto electricians twice in its life (mine has never been out of...

Spoke to an auto electrician on the phone and he was disgusted with how things have gone - he said he feels sick when he sees all the good parts that just get thrown in the bin! The throwaway society has gotten out of control - I was always told that reuse is better than recycle (or landfill!)...

Does anyone who knows a bit about this, think the rear slip ring may still have some life in it (see pic)??? Clean and then sand with 00 sand paper perhaps? Or has it gone full depth?

Hard to tell!!! Nothing obvious! Haven't taken the vacuum pump off yet as I was a bit disappointed when I saw the rear slip ring!:( I might learn to solder (not sure if I have to?) in order to fix the slip rings, in the meantime I'll pick-up a second hand working unit and put a new brush box...

Brushes (originals) were worn down as you'd expect, but looks like the rear slip-ring is gone! Bearings and the rest all looked good (tested rectifier and windings). The rear carbon brush was worn down around 2-3mm more than the front one, and it looks like that was because of oil/grit acting...

Okay, alternator was a bit oily (original Denso alternator with original brushes for 260,000km). Removed the back tin cover and then removed the brush box holder. Brushes were worn down as you would expect, but what I really noticed was some sludge - oil, grit and the orange hue of copper...

Now! Oil! I put a new front camshaft seal in a while ago, but there was historical oil build-up from that I know. What are the other sources of oil? Assuming vacuum pump lip seal??? Assuming vacuum pump oil feed hose inlet - copper washers worn perhaps??? Anything I should check regards oil?

Okay, it's out (first time in 18 years!) - nothing damaged in the process - yeah! (Have to take care working on old stuff, particularly plastic (multiplug) - goes hard and brittle with all that oil and heat!). Would have hated for the multiplug or radiator to be damaged! Wiped up the...

Got it out - wife assisted - better and safer with three hands! I didn't want to damage anything, especially those 1cm diameter hard plastic coolant lines coming from the radiator! Anyway, my wife just bent/twisted the EGR cooler bottom coolant hose (1" diameter) right back and out of the way...

Got the clip (multiplug) off!:p Removed the intercooler EGR bypass elbow to get better access. Sprayed multiplug with WD-40 (using nozzle) and left for several minutes. Got a cloth to grip the oil-hardened plastic multiplug better; squeezed the top part of the multiplug down firmly and tried...

This, but I used a wobble extension with the thin walled six-sided socket to get a little bit of articulation - did it all from underneath. Soaked the area with penetrant before-hand, and put a little ball of Blu Tac inside the socket so I didn't drop the bolt.

T50 3/8" socket with a short extension - all good getting the bottom bolt out. Removing the hardened/stiff vacuum pump drain line and the vaccuum line (to servo) required the hair dryer on high for three minutes to soften those stubborn buggers!!! Last thing I'm trying to get off now is that...

Okay, seen a second-hand Denso working alternator from a 2003 Disco Td5 that has done similar mileage to mine (260,000km) for sale for 70AUD (38.50GBP) that I can pick-up locally tomorrow - obviously I could still be in the same boat in a short time though (at the very least the brushes would be...

2003 Disco 2 Td5 (16P) Okay, alternator area is quite oily. I know there is a seal between the vacuum pump and the alternator itself, and there is also a small o-ring on the oil feed hose that goes between the top of the engine and the vacuum pump. Are either of these two spots where the oil...

Okay, had a loose 10mm socket (1/2" drive) lying around! Detached the oil line from the cylinder head - 14mm open-ended spanner. (This is the one that needs the replacement o-ring). Enough room to tackle the 10mm bolt - this time with 1/2" ratchet and extension. All good - 10mm bolt removed...

Got the bugger (positive lead) off! Ended up using a 1/2" ratchet + 5" extension + 5" wobble extension + 13mm six-sided socket. Just in an awkward position! Didn't have to remove the fuel cooler (but of course battery, battery box, ECU, intercooler hose, fan, fan belt and tensioner all...

Okay, cannot budge the 13mm nut securing the positive lead to the alternator (underneath the rubber cover)! Difficult spot to access! Using 13mm socket and extension with a 1/4" ratchet. Cant' budge the bugger! If you have taken yours off, do you have any suggestions?

Never measured AC at the time - didn't think to do that.

"Checked battery terminals - nice and secure. Got multimeter and checked battery (battery only six months old) - 12.1V (DC). Turned ignition on and measured again: 11.8V (DC), then 2 seconds later it jumped to 12.9V (DC) with a change in sound!" Removed battery and trickle charged - now 12.6V...