Ok, well, during my early morn diagnostic session I removed that little
two screw 'module' as you called it, Mark.  There seems to be a contact
with a spring..that was stuck to the module..Also, there fell out a washer
with a "tail" on it..I think from beneath one of the fixing screws for that
brush module..this washer is aluminum and has a "leg" about the same size
as the washer's diameter that comes out on a tangent from the washer
itself.  Is this important?  It looks to be somekinda contact or ground.  I
still get no charge after tweeking the brushes, but could this washer have
something to do with that?  I put it back under the screw that I *think* it
came from, and I can't see anywhere obvious to make it any other way, but?..
  So, it looks like off to the autoparts to charge up both my batteries and
to try to find an alternator 'close by'...Or to head out after charging and
try to 'limp home' about 7 hours...
  Thanks,
  Don Hanson

On Mon, 24 Sep 2007 05:00:33 -0700, Mark Drillock <drillock@EARTHLINK.NET>
wrote:

>Don, this sounds like the alternator brushes have reached the end of
>their travel. If you remove the 2 small screws and pull out the
>brush/regulator module you can see this. Also, see if you can pull the
>brushes out a tiny bit with pliers as long as you have it out. This may
>let you get things working again long enough to get to a parts store for
>a new module or even all the way home.
>
>Unhook battery ground lead first.
>
>The brushes are spring loaded and connected to the reg module with a
>wire braid. When the brushes get too worn, the braid is like a leash,
>keeping them from coming out past a certain point. You can stretch the
>leash slightly, but don't break it since it is the electrical wire for
>the brush.
>
>The same brush/regulator module is used in Bosch alternators of most VWs
>and many other European cars. I carry a spare replacement in my Vanagons.
>
>The O2 light is wired in parallel with the alternator light. If both
>come on it is because the alternator has stopped charging.
>
>Mark
>