'57 generator conversion

[ward 57]

I know this was discussed in a different thread with a different title. I have learned I have an auto generator instead of the T-Bird specific generator. I have the kit to covert it and new brushes to install in the process.
My question is do I need to re-lubricate the bearings? The end cap will be off so easy to get to. Do I need to also remove the armature to get to the rear bearings or let them be as no issues at this time.
If I do choose to lube the bearings, what do I use?

[ward 57]

Well, as it turns out, the bearings are permanently sealed bearings. No need to lube them. I have received the bearings and brush springs, everything on hand to convert the end plate and rebuild it this spring when it warms up.

[ward 57]

OK. I've got the generator out and disassembled. I'm not seeing what I expected. A much more complicated spring assembly and the output post is riveted to the end plate. I don't see how I can convert it. The brushes have 50K on them and only 1/2 worn. What now? just put it back together after replacing the bearings and bushings and put it back together ?

[swatson999]

This is like kismet. I *just* rebuilt one of the generators for my 56 (car came with a spare), and it has the *exact* same setup (which obviously doesn't use the type of springs sold by the usual places), and I found the same issue...no way to convert it with the little kit that moves the armature post, since the monkey-motion spring set-up is essentially permanently installed.

I just replaced the brushes, bearings and armature and reassembled it. One hitch that I found was that one set of brushes was too wide for the "holder" (that set was from CASCO), but I had another set that came with the new armature that fit (from Dennis Carpenter).

I have no idea which year or model or whatever started using this design. Maybe post-56, since the Shop Manual references and depicts the other style (as does the parts manual/drawings).

ETA: looks like this

Just looked at the one on the car, and it's the other style.

[ward 57]

Does anybody have a proper spare stamped end plate? I don't like having that output stud that close to the block.

[Joe Johnston]

I had one for years and never swapped it because I never had a problem. YES it was close, but never an issue. I switched to a Delco 3 wire alternator and sold everything many years ago. Change if you must, but it was not a priority for me.

[Jimntempe]

Does anybody have a proper spare stamped end plate? I don't like having that output stud that close to the block.

Is it possible to grind off 1/16" to 1/8" from the stud and use a thin nut to gain more clearance? would there still be enough "stud" left to do that?

[ward 57]

Anybody have any theories why so many of us have car generators instead of T-Bird specific? They are so easy to refurbish with brushes & bearings. Why replace them instead with one off the shelf and not knowing the difference?

[Jimntempe]

Anybody have any theories why so many of us have car generators instead of T-Bird specific? They are so easy to refurbish with brushes & bearings. Why replace them instead with one off the shelf and not knowing the difference?

My theory would be that they usually needed replacement around 40K and most people don't do their own work. So many of these cars are on their 3rd replacement. Since the regular car generators apparently will fit, even if a close fit, a lot of mechanics didn't know there was a difference and just slapped a generic ford generator on. Back in the 50's and 60's car repair wasn't nearly as specialized as it is now and this kind of RR was very commonly done at the owners local full-service gas stations, most of which had two bays and at least one mechanic working there. Many may not realize just how common it was back in that day for people who mostly drove short trips to drop their car off just to have the battery recharged or to include a battery recharge with every 2000-mile oil change.

[MarkR]

Also I doubt your average “filling station” would keep a Tbird generator on the shelf even if they knew there was a difference. Using a passenger car generator had always worked and they had a happy customer without a wait. I know the terminal is too close for comfort but I don’t know of anyone who had problem. Not saying it couldn’t happen.

[ward 57]

Replace, not repair has been around for ages especially when the mechanics were paid by the job on how long it would take to get it done as quick as possible to beat the 'book' time. Not the time it actually took to do it right. We know all about that. Plus additional parts sales.
My first job was working in one of those gas stations as a pump jockey. The crass humor from the mechanics was something to this naive young teenager.

[ward 57]

Found an end plate on Ebay from classic restorations. $75 + tax & shipping and already converted. They note it's their last one.
Now I have a conversion kit brushes & springs & end plate I no longer need.

[ward 57]

Got 'er done, and it actually works. NOS T-Bird end plate. I did dress the brushes a bit per the shop manual and polished the commutator with # 1000 sandpaper.

[ward 57]

OK job done well. But I have another question to you gurus out there. After warmed up the battery was showing 12.3v at idle on a full charge. After I shut it down it was showing 12.6V. Does the ignition system actually use that much current?

[55blacktie]

Is the generator light coming on at idle (common)? Above idle you should see 14.