'91 coupe 7A motor alternator brush pack stops charging when half worn

[cgharibo]

I have had my car since new. About every 50k miles I change the alternator brush pack and all is good again and I get a good charge.

I again changed the brush pack today and examined all the older brush packs that I had saved and they all stop charging when half worn. They all look half-used and look like they can be pushed out more or something else can be done to make them last longer.

The question is, is there a longer lasting brush pack or can I modify the brush pack so it uses more of the brush before it stops working and save some time for everyone?

[John.]

Are you ably to fit a small spacer to increase the spring pressure/tension, maybe that might help?...........assuming it's this that is causing the problem?

[RedV6]

I wonder if you live in a dusty landscape or generally drive on dusty or sandy roads. Perhaps the slip ring is also worn so as a combination of half worn brushes and worn slip ring the increase in working clearance is having an effect

[Tractor Dave]

I have this issue with my Bosch angle grinder. The cheap Chinese brushes only last a few months. Are you fitting genuine brushes?

[RedV6]

Yea that's certainly possible. Although I am never sure if the Chinese stuff is just plain rubbish to make it cheap or a genuine marketing strategy, to under cut western manufacturing so it goes down the pan and as a bonus! The Chinese get to sell multiple as the components life span is so short.
Which ever way you look at it its a sad decline in a very short period for us. And its all our fault..!