Chrysler Full-Size Vans 1967-1988 Repair Guide

Regulator

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REMOVAL & INSTALLATION



  1. Disconnect the battery ground cable at the battery negative terminal.
  2.  
  3. Disconnect the alternator output (BAT) and field (FLD) leads, then disconnect the alternator ground wire.
  4.  
  5. Remove the alternator mounting bracket bolts and remove the alternator.
  6.  
  7. Installation is the reverse of the above. Adjust the alternator drive belt tension. Check the alternator and regulator circuits and perform any necessary adjustment.
  8.  

1970-88 with an Electronic Regulator

See Figure 1



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Fig. Fig. 1: Electronic voltage regulator used on 1970-88 vehicles

  1. Release the spring clips and pull off the regulator wiring plug.
  2.  
  3. Unbolt and remove the regulator.
  4.  
  5. Installation is he reverse of removal. Be sure that the spring clips engage the wiring plug.
  6.  

ADJUSTMENTS



1967-69 Mechanical Regulator Only

See Figures 2 through 7



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Fig. Fig. 2: If cover removal is necessary for adjustment, remove the retaining screws



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Fig. Fig. 3: Lift the cover off for access to the internal components



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Fig. Fig. 4: Use a wire gauge to measure the gap(s) ...



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Fig. Fig. 5: ... and, if necessary, bend the contact to adjust the gap(s)



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Fig. Fig. 6: Always double check the gap(s) after an adjustment has been made



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Fig. Fig. 7: When installing the cover, make sure the rubber gasket is in position to avoid any water damage

Normally, when the voltage regulator is suspected of being the cause of a vehicle charging system problem, the procedure is to remove the old unit and replace it with a new or reconditioned regulator. However, since these regulators are adjustable, it is advisable to perform the adjustments before removing the old unit. If the problem cannot be corrected easily by adjusting the voltage regulator, and no other possible causes of the problem can be found, the old regulator should then be replaced. In addition, adjustment procedures can be used when installing a new regulator to check to be sure that the voltage setting is correct.

Do not remove the regulator or regulator cover to make the voltage adjustment. The stop in the regulator cover will limit the voltage adjustment range and the voltage adjusting screw should not be forced beyond this point.

  1. Adjust the lower contact voltage setting as necessary by turning the adjustment screw clockwise to increase the voltage or counter-clockwise to decrease the voltage.
  2.  

If Step 1 does not bring the voltage regulator to within specifications, proceed to Step 2.

  1. Remove the regulator cover and measure the upper contact point gap with a wire gauge. The point gap should be 0.014" +- 0.004". Adjust the upper contact gap as necessary by bending the armature upper contact bracket, making sure the contacts are in alignment. If the upper contact gap is correct and a difference of 0.02-0.7 volts exists between the upper and lower points, adjust the air gap as follows:
  2.  
  3. If the difference is above 0.7 volts, reduce the air gapy by bending down the fixed contact bracket; if the difference is below 0.2 volts, increase the air gap by bending the fixed contact bracket up.
  4.  
  5. Connect a small dry cell test lamp in series with a IGN and FLD terminals of the voltage regulator. Insert a 0.032" wire gauge between the regulator armature and the core of the voltage coil next to the stop on the armature. Press down on the armature until the armature contacts the wire gauge. The lower contacts should just open and the test lamp should be dim. With the air gap adjusted, a 0.042" wire gauge cannot be inserted between the armature and voltage core.
  6.  
  7. Before installing the cover screws, make sure the rubber grommet is engaged over the voltage adjustment screw.
  8.  

 
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