Dynamo front bearing replacement

[DRMM]

I'm sure this has been asked many times...
Ive got as far as getting the endplate off the armature...
I understand i have to drill the rivets out holding the bearing cover plate on.... Do i drill the heads off, or their bottoms from the underneath?
... I'll try to post a pic...

[geoberni]

As you're asking, I assume you don't have a copy of the relevant Lucas Workshop Manual.

Visit this website.
Download the Dynamo section (there might be others you'd like too).
Go to page 10 of the pdf, page 9 of the document, where it is all detailed.

https://www.lrsoc.com/web/portfolio-ite ... op-manual/

[DRMM]

... Thanks!

...ah found a post says drill the heads off... Are they ally rivets?
...edit - theyre steel, not ally...

Also what is the bearing? 6202 or 6201 - Ive seen both quoted?

[geoberni]

... Thanks!

...ah found a post says drill the heads off... Are they ally rivets?
...edit - theyre steel, not ally...

Also what is the bearing? 6202 or 6201 - Ive seen both quoted?

I have no idea, because I don't recognise those 4 digit numbers, Lucas part numbers are invariably 6 digit .....

AFAIA, the only bearing ever fitted to the Drive End of the C39 Dynamo (and several others), is the 189307, which is widely listed online.

[Bill_qaz]

6202 6201 are Std metric bearing number RS rubber sealed 2RS TWO rubber sealed

Screenshot_20260224-193151_Google.jpg (134.51 KiB) Viewed 58087 times

[svenedin]

Lots of suppliers supply the ball bearing for the Lucas C39 and C40 dynamos but they seem to use their own part numbers. If the ball bearing needs replacing then the bush at the other end is probably worn as well. If it is, the spindle will have side to side play.

https://www.jrwadhams.co.uk/product/dyn ... -c40-html/ LU242672

https://www.jrwadhams.co.uk/product/dyn ... -c40-html/ LU227818

Stephen

[Bill_qaz]

... Thanks!

...ah found a post says drill the heads off... Are they ally rivets?
...edit - theyre steel, not ally...

Also what is the bearing? 6202 or 6201 - Ive seen both quoted?

Lucas Dynamo E3 Drive End Bearing 189307 (6202-2RS) - Classic Fasteners https://share.google/iROVWERzfshWJFZzR

[svenedin]

You might want to have a look at these 2 videos on the Lucas C40. The first video is strip down and the second rebuild.

https://www.youtube.com/watch?v=rvWstHAV-iY

https://www.youtube.com/watch?v=SwBtds0v6C8

Stephen

[Mervin]

I drilled out the rivets from the inside of the end plate. I can't help with the rivet's size, but I purchased some steel rivets, from an eBay seller, slightly smaller than the hole diameter and cut them to length. Supported the "domed end(s)" and peen/pein the other end using a ball pein/peen hammer.
I fitted an SKF 6202-Z/C3 bearing whichis "shielded" on one side only. The SKF6202-C3 is open.
To remove the bronze bush from the other end cover, after dismantling the dynamo, I screwed in a 5/8" BSF tap, gripped the tap's square end in a vice, and using a rubber mallet, knocked the end cover off, leaving the bush on the tap.

[Mervin]

This is a non Lucas end cover I "practised" on first. The bearing was greased and may be removed, if necessary, to use in a genuine cover. The rivet "domes" are slightly flat from being supported on a steel surface when peining the other ends.

dynamo cover.jpg (283.68 KiB) Viewed 57893 times

dynamo cover 1.jpg (269.59 KiB) Viewed 57893 times

[svenedin]

Do the rivets really need to be steel? Wouldn’t aluminium pop rivets suffice? In some variants of the C40 the bearing is just held in place with a circlip.

Stephen

[Mervin]

Steel rivets possibly not necessary Stephen, but I certainly wouldn't risk using pop rivets. I would suggest using similar to what Lucas did originally is preferable (steel). It's not really that difficult to bash the heck out of them with a ball pein hammer. The end result is not as neat but the hammered ends can't be seen on assembly.
Yes, I have seen the circlip method, much less hassle.
In the words of Dirty Harry - "Are you feeling lucky p--k."

[oliver90owner]

Steel rivets possibly not necessary Stephen, but I certainly wouldn't risk using pop rivets. I would suggest using similar to what Lucas did originally is preferable (steel). It's not really that difficult to bash the heck out of them with a ball pein hammer. The end result is not as neat but the hammered ends can't be seen on assembly.
Yes, I have seen the circlip method, much less hassle.
In the words of Dirty Harry - "Are you feeling lucky p--k."

No need to go bashing around. Rivet snaps are readily available and make a far easier/better job. I’ve replaced a lot of cutter sections, on mowing machines and combine harvesters, in my time…

[DRMM]

Thank yous for all those replies... Ive just got back to it...

So it is is it, okay to drill out those rivets from the other end then, cos i can't find my centre punch?...
The other thing I thought is whether i could grind them off (I have an angle grinder)?
Im a bit out of practice with all this stuff

I am tempted to just buy one of those new dynamos from ESM. Does anyone on here know where they are made (I would prefer to keep it original as far as poss)?

[svenedin]

Thank yous for all those replies... Ive just got back to it...

So it is is it, okay to drill out those rivets from the other end then, cos i can't find my centre punch?...
The other thing I thought is whether i could grind them off (I have an angle grinder)?
Im a bit out of practice with all this stuff

I am tempted to just buy one of those new dynamos from ESM. Does anyone on here know where they are made (I would prefer to keep it original as far as poss)?

New dynamos available are Chinese/Far East/Indian made except a few that are remanufactured genuine Lucas. If you want a genuine Lucas one you do have to seek them out.

Here's a genuine C40 for instance: https://www.autoelectricsupplies.co.uk/ ... c40-dynamo

There are also sellers of reconditioned Lucas equipment on eBay.

Or there are still a few businesses (they used to be common) that will overhaul your own unit or supply on exchange.

Given the cost of a reconditioned unit it makes a lot of sense to overhaul the dynamo yourself if you are able to. The one thing you MUST check before you start overhauling a dynamo in unknown condition is whether the field coils are intact. If they are not serviceable, then replacing the coils is NOT a DIY job due to how tight the pole shoes are and need to be (they require a special tool). The field coils can deteriorate with age due to the varnish insulation degrading; oil contamination or breaks in the fine wires. If this happens the coils are scrap and need to be replaced.

Stephen

[Bill_qaz]

https://ebay.us/m/zg5cJi

Maybe of interest, I have no connection, just noticed it