How to Rewind a Stator Made Easy

If your vehicle has a weak spark when you start it, its stator exciter may need rewinding. An important component of the alternator on all motor vehicles, the stator exciter consists of tightly wound layers of thin-gauge wire. When you start a vehicle, the stators wires react and produce the electrical spark a vehicle needs to operate. A big spark indicates that a stator is working properly, producing a standard amount of RPM voltage. A low spark -- causing lower voltage levels -- signals that the stators wiring is loose or faulty and that it needs rewinding. You can have a mechanic rewind the stator, or, you can follow steps to rewind it yourself. This is not unusually difficult to do and should only take a few hours to complete.

Instructions

1

Unwind and remove the old wiring. A stator has three sets of six cores. The sets of cores will have a labeling of 1, 2 and 3, respectively. While unwinding, pay attention to how many times the wire is wrapped around each core in a set, and the direction it is going in so that you can replicate the exact pattern when you rewind. Take close-up pictures of the stator wiring to use as a reference if necessary. Take the clamp off that connects the wires to the stator. Cut a section of the wire and begin unwinding it. Remove all of the cloth installation that is wrapped around the wires and set it aside to use later.

2

Inspect the stator after removing all of the wires. Look for any cracks or chips in the epoxy on the stator. Fill in any cracks with epoxy. Allow the epoxy to dry before beginning to apply the new wiring.

3

Unroll about 13 feet of 17-gauge wire. Do not cut it. Apply a piece of masking tape around the end of the wire and write 1 In on the tape using a permanent black marker. Measure 6 to 8 inches down from the end of the wire using a tape measure. Mark that point by drawing a small line on it with the marker. From that point measure down 11 feet and 2 inches. Mark this point with the marker.

4

Place the end of the wire, marked 1 In, on the beginning edge of the first core of the stator that is marked 1. Begin tightly winding the wire around counterclockwise until you reach the mark you made on the wire that indicates the 11 feet and 2 inches position. This indicates that you have finished wrapping the first 1 core.

5

Stretch the wire over to the next 1 core. Measure down another 11 feet and 2 inches. Make a small mark on the wire at this measurement point with the black marker. Wrap the wire around the second core until you reach the black marker line that represents the end of wrapping for the second core. A stator usually has three sets of wire levels consisting of six cores. Continue the same process of measuring and marking 11 feet and 2 inches and wrapping the wire for the remaining four cores. After wrapping the last core, measure out 6 to 8 inches of wire and cut it at this measurement. Place a piece of tape around the end of the wire and write 1 Out on it.

6

Complete the same wrapping process you used for the 1 set of cores to complete the 2 and 3 sets. Make sure you measure, mark and wrap in the exact same manner as before, except write 2 or 3 on the In and Out masking tape. When you are done with all three sets, you should have six wires sticking up from the stator with In or Out marked on the masking tape of each wire end.

7

Grab the wires marked 1 In and 3 Out and put them together. Cover the wires with a piece of the cloth installation you set aside earlier. Push the wires between the number 1 and 3 cores above the scribe mark.

8

Grab the wires labeled 1 Out and 2 In. Place them together and wrap a piece of cloth installation around them. Push them between the 1 and 3 cores. Complete the same process with the 2 Out and 3 In wires. Push them between the 1 and 2 cores. When you are done combining all six of the protruding wires, there should be three sets of wires sticking out the side of the stator.

9

Apply epoxy on all sets of coiled wires. Make sure you cover the wires completely to keep them coiled in place. Do not put epoxy on the three sets of wire ends that are sticking out the side. Let the epoxy dry overnight.

10

Fold the three sets of protruding wire ends down in the direction of the mounting screw where the clamp attaches to the wires. Cut each set until its length stops at the beginning of the screw hole. Use the wire strippers to remove a -inch piece from the end covering of each wire set.

11

Place the cloth insulator over the ends of the three wire sets. Look for three yellow wires coming from the stator. Using a soldering gun, solder the end of a wire set to a yellow wire. Continue soldering until each set is connected to one yellow wire. Cover each wire connection with a cloth insulator.