[oldskewel]

I once had the alternator out of my 2011 LX, so I opened it up to check how much of the brushes were left. My conclusion was that they would run out around 170k miles, so I plan to replace them before then. They wear out just like your tires do, at a fairly steady rate.

Based on your 160k mileage, I'd consider that a possibility for you - that your brushes are on the limit of wearing out. That would give intermittent lack of charging, and probably all the symptoms you're facing.

It seems that nobody else on here rebuilds their own alternators, but it is very easy.

Here's a full kit for my alternator (might be yours too):

Alternator Rebuild Kit for 2011-2013 Honda Odyssey, 2012-2015 Pilot, 2012-2014 Ridgeline Regulator, Brush Holder, Brushes, Bearings - 11573RK

<h3>Description</h3> <h4>Alternator Kit; Regulator, Brushes, Bearing Kit</h4> <ul> <li>Voltage Regulator B-Circuit, IG-C-L-FR Terminals, 14.35 Voltage Set Point, Replacing Denso 126600-3650, Other IN6365, 230-52150, AND6148, 80904501, VRH2005-149 </li> <li>Quality WBD Bearing 53514...

www.maniacelectricmotors.com

Just the brush assembly for $9.90 shipped.

Brush Holder Assembly with Brushes for Denso Alternators Replacing Denso # 021620-3030 - 74909205

<h3>Brush Holder Assembly for Denso Alternator</h3 Mount Hole Distance 25.5mm Height 29.5 <br> Replacing: Denso 021620-3030, Other 39-8206 <h3>Unit #s </h3> Acura 31100-RX0-A01, 31100-RX0-A01RM Audi, Volkswagen 7B0-903-015C, 7B0-903-015CXRMN, 7B0-998-015-A BMW 12-31-7-591-529, 12-31-7-591-530...

www.maniacelectricmotors.com

And if you're willing to solder (this is pretty tricky, not like normal soldering), just the brushes for $3.99 shipped.

Alternator Brushes Nippondenso (2 Pack) 4.8-5mm Tall x 7mm Wide x 15/14mm Long x 48mm Long Lead - 7390901

<h3>2 Brushes For Denso Alternator</h3> 4.8-5mm Tall x 7mm Wide x 15/14mm Long x 48mm Long <h3>Replaces</h3> WAI New 38-8201, 021660-0510, 38-8201-1, 38-8201-2, 38-8201-SM Daihatsu Motor Co 27370-87302-000, 27371-63020-000, 27371-70300-000, 27371-87501-000 Denso 021660-0390, 021660-0510 GM...

www.maniacelectricmotors.com

 

[oldskewel]

There is no oil leak. The connection seems fine too. I guess I will follow Oldskewel's recommendation, to order a rebuild kit and rebuild it myself.

Then that will be two of us!
I might buy the full kit, but will probably just buy the brush assembly ($10), and that's what I'd recommend for most people.
Good luck!

 

[oldskewel]

Then that will be two of us!
I might buy the full kit, but will probably just buy the brush assembly ($10), and that's what I'd recommend for most people.
Good luck!

Confirming I went ahead and bought and installed that brush assembly yesterday. Just taking care of some things while I had a little time (replaced the spool valve gaskets too - spool valve gaskets ).
Confirming my estimates from before:

• based on measuring brush length at around 90k miles, I predicted they'd last to 170k. From what they looked like at 138k, I'd stick with that prediction.
• ease of installation is <1/10th as difficult as removing the alternator. Maybe even easier. Just 3x 8mm nuts to remove the back cover on the alternator. Two PH2 (or JIS) screws to remove the brush assembly. A little trick to put a pin in to hold the brushes back while putting the brush holder back over the slip rings. And then 2 screws back in, back cover back on, 3 nuts on, and you are done.

Alternator is working fine, and bearings felt smooth, so I did no electrical testing (all that is basically go/no go, to check for a failed component) do not have any plans to do a further rebuild of it.

So now the alternator should last to 300k miles, and at the slower rate we now put miles on it, it is sure to run out of an available gasoline supply before alternator brush material.