this is actually regarding my 2.0 zetec focus... the focus forums are pretty useless when it comes to actually getting answers, rf always rocks.

anyways, my focus alternator died last week. I ordered a brand new, upgrade replacement from PA. It arrived today, and installation went smoothly. After I initially started up the focus, I smelled an odd smell... not sulfury or burny, maybe more of an electrical smell. Briefly after, there was some very slight, almost non-visible smoking. I drove the car for about 2 miles, and then let it idle for 10 minutes and the smoking is completely gone, and the smell is going away.

my question is, have you guys aever experienced this kind of thing with a brand new alternator... like an initial break-in smell or anything? Should I still be concerned even if it seems to be going away so quickly?

Thanks for any replies!

 

might just be the brushes burning off some type of lubricant to keep the parts from rusting

 

agree

i have, i wouldn't worry about it unless the smell doesn't go away, give it a day or two

 

thanks for the quick responses guys... i just let it idle for another 15 minutes and i can barely smell anything now.

 

i know that on my focus when i had it, the positive battery cable at the battery melted......might check there too.

 

It's possible that there was some contamination in the rotor/stator assy or even a little lubrication on the brushes/rings that got hot & smoked.

Most rotors & stators are coated in a varnish like epoxy material to keep the wires from rusting...there could have been a little bit that didn't get machined off properly or a chunk of the varnish/epoxy got stuck in one of those crevices.

Give it another run & if nothing has melted & everything is working properly (electronically) you should be ok.

My 200a alternator came boxed up with packing peanuts packed in every hole on the thing. I blew it out with compressed air before I installed it & I still smelled a slight "electrical ozone" for a day or so.

Hope this helps.