Failed alternator -- rescued by Toyota

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Hi John,

As you say, parts will eventually fail. The game we play is gambling on them lasting "for a bit longer".
If your trekking is to remote locations beyond the "Toyota network" then the odds are shifted a bit and not in your favour.
In industry, where the cost of production stoppage is expensive, then preventative maintenance is practised and the game plan is to maintain or replace just before the damned machine fails. These intervals are largely determined by experience of earlier failures.

I would think that at 193,719km the alternator may be getting a bit close to a failure. Mind you, some preventative maintenance at an earlier date may have prevented an inconvenient total failure. It may have only needed new brushes and some bearing TL&C. But the human tendency is to hang off for "a bit longer" as it "seems to be going alright".

In my own case and the Troopy, a couple of years ago I decided to do just that.... give the alternator a birthday party. After all, these things are spinning constantly at about 6000rpm in a stinking hot environment. However, in getting the alternator out I was clumsy and broke the copper stud of the main connexion. With a broken complex-manufactured component and little time before trip departure I opted to replace it with a new after-market alternator, about $300 I think. So that was the end of that and the start of a comfortable feeling, I can justify anything if need be! lol

A year or so later, the starter motor was exhibiting initiation problems. Maybe only the integral solenoid contacts and right up my alley to service but then I rationalised that (a) the solenoid contacts would need to be obtained and replaced, (b) the brushes would likely need replacing, (c) the commutator may need refacing in a lathe, (d) the bearings could likely do a replacement. After all, this thing hangs right down at the bottom of the motor and has endured the dunkings of many creek crossings and sundry trials. So this time I went straight to a replacement product. Again, "Oh, What a Feeling". Except it was not a genuine Toyota part replacement.

However, to answer your specific question... "What electrical tests or examinations" you may have done before departing, I can only say that unless you have the necessary expertise, and maybe equipment, then there is little you can do to either ascertain worthiness or carry out preventative maintenance of such parts. And alas, to have this done for you by a skilled mechanic may cost more than replacement and with no assurance of reliability because as an electrical wiz, I know only too well that some electrical failures are next-to impossible to diagnose, they will hit when Murphy says so!

But I would say to one-and-all, heed my words above about the stresses on your alternators and carry out either thorough maintenance or replacement at an appropriate time..... whenever that might be. lol

If travelling with others..... you could probally swap batteries every 3 or 4 hours.... most would have an aux as well.

I carry a set of brushes for my alternator. That may save me but also could be a diode or regulator or bearing. Its one of those items that gives no warning, the warning light just comes on when it fails. I got about 350,000 ks out of my original Patrol alternator, I should really have a look at it and carry with me. They are fairly small so maybe its something we all should carry a spare of! Michael

You can only wonder why you would to a Toyota dealer for an alternator!
Auto electrician would probably be half to two thirds the price, or buy one yourself for a quarter the price.
Obviously you have to much money and need to lighten your financial 'burden'.

Indo
I think that distance is a fair distance without trouble. However, as Alan said , failures can be foreseen and preventative measures implemented long before the item actually fails. I owned a HJ 61 for many years and replaced the alternator bearings at just over 100k . Starter also had new bearings and a decent amount of Nulon grease to all relative parts. Makes a big difference to current draw on startup and lengthens stater life. With alternators I carry a diode pack from earlier Bosch alternator which is fitted with a computer fan. This can be fairly easily wired to the stator in an emergency to continue charge to vitals. I also normally take a small Honda whipper snipper engine with small alt attached. That will run and charge the system. At Katherine I once saw an 80 series owner needing an alternator. Toyota had one for his at $920. Most breakdowns are because of lack of forward planning and maintenance. All is well while all is well! PS. Does your vehicle actually have an Electric fuel pump?????

Yes Dave B18, Coonabarabran is a very friendly and well-serviced town of about 2,500 people. The alternatives were considered but neither the auto electrician in town nor Coonabarabran Toyota had the particular alternator in stock. And yes, you are quite right -- it was an expensive experience. And yes -- I may have done a better deal on the item by waiting for the three days quoted for an alternator to be delivered in Coonabarabran. Given that I was also responsible for the onwards accommodation bookings and cancellation fees for our convoy throughout the rest of the fixed itinerary, the decision was to avoid delay and disruption and move on – this was both less disruptive and more economic in the circumstances.

However, Allan B and RMD are right and Dave B18 also has made strong points in your response in another string Do I have all the spares I should be carrying? – all to the effect that more thoughtful preventative maintenance in the first place would have resulted in less risk, less requirements for quick decisions under pressure on the road and certainly less cost.

Guilty as charged and I got off lightly given the location was not really "remote" – but lesson learnt!

RMD -- the fuel pump for the 1HD-FTE engine in the HDJ100's is well-described by Ron N and others in replies to the string Typical Diesel Pump Lifetime This gives rise to even more thoughts about preventative maintenance and also the need for a bit more personal research on my part.

John P.

3 weeks ago my alternator in the 100s died as well - 194,000 km. My mechanic advised using Toyota replacement. I stripped the old one down - it was a diode that was burnt out. Expensive exercise, just short of $950 in Perth which included replacing the three belts . I was returning from the bush at the time and I was thinking of hooking up a portable solar panel to the primary battery hopefully would get me back to civilization. As it was, the vehicle died in my driveway - down to below 6v.

I think the OP did ok, had a convoy to help and wants to know how to avoid a repeat. Put simply you can’t load a car up with 100kg of spares or Murphy’s law say, it will be the part that you didn’t bring.

2016 our friends in their coaster and us stoped at Barkly Homestead. His double fan belt was slipping just a little when moving from stationary. He tried adjusting the adjuster but the bolt broke! We spoke to the manager and he suggested we look at the 80 wrecks at the back, we did and found a Camry with the same mounts and bolt.

The moral of the story, of a problem appears that can be left to be repaired ata major town then leave it till then. The belt wasn’t slipping while cruising.

In the OPs case an alternator is a major item so optionsare limited.