Posted by LJD on December 09, 2011 at 13:38:39 from (67.142.130.35):
I posted earlier about our trip to MacFaddens auction yard today. I didn't mention our car problems on the way home. We almost did not make it. This is a strange one !
I've been doing mechanical work for 50 years - but this is a new one for me. If I hadn't seen it myself, I would NOT have believed it.
This is on my newest Subaru. A 2002 Impreza Outback with a 2.5. I just had the engine out a few weeks ago and put a new clutch in, along with a timing belt.
Our family went for a drive about 25 miles from home. On the way back, on a unplowed snowy dirt road we hit a big bump and the car bottom out for a second. Just after that, the tach and speedometer started going crazy and the ABS light came on. Then the car started losing power. I kept it going and when we starting coming down a hill, I turned off the engine in an attempt to "reboot" the electrical system. Well . . . it was dead and would not turn over. Good thing I was coming down a hill. I roll-started it and limped back home. When I got to my repair shop, I could barely keep it running. It would not idle, and was spitting, breaking up and sounded like it was running on maybe two cylinders.
I got it in the shop. Checked the battery and it only had 11 volts - i.e. stone dead. I put another battery in it and it started right up and ran fine. I then tried to pull codes of the computer and there were none. Then, scratching my head a bit - I stuck a voltmeter on the battery while running. 12.6 volts - i.e. not good and going dead. I checked voltage at the alternator post to alternator case ground and got 14.8 volts. This did not seem possible. I then checked voltage between the alternator main post and engine block ground and only got 12.6 volts. I then took a sharp knife, stuck it at the seam where the alternator is bolted against the engine block and sparks flew. Seems the alternator actually lost all electrical contact with the engine although it is bolted up tightly. I would of not believed this was possible. I then ran a jumper-cable from the alternator case (after I filed a clean spot) to the battery ground and battery voltage started climbing right up.
I call this bad Subaru engineering. The "no charge" light only comes on when the alternator output lead falls below proper charge voltage. Voltage to the remaining car's electrical system is NOT monitored. So, what happened here is - the alternator made proper voltage BUT the battery was not charging and went stone dead. We almost did not make it home yet the "no charge" light never came on.
I've had Subarus so rusty the drive axles broke off - yet I've never, ever, seen an alternator lose contact with an engine it was bolted to when tight. I would of said it wasn't possible. Now I've got to take it off and wire-brush all the metal surfaces where it contacts the engine. Funny thing is . . . this is my cleanest almost rust-free Subaru. I will note that when I pulled the engine to put a new clutch in, the aluminum engine was almost "welded" to the transmission with corrosion. I had to use to big chisels to separate. The steel bolts also pulled out the aluminum threads in the engine which I had to fix. Another design flaw as I see it. Steel touching aluminum when wet causes a galvanic reaction. Dis-similar metal parts when touching should at least be treated with an anti-corrosive compound and these surely were not.
I wonder how many other new cars made in the USA are cutting corners like this? All my older Subarus were made in Japan but this one was made in the USA.
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