Battery Light Flickering over 3k rpm

[06YarisRS]

Originally Posted by 07GOKRT

Hi All, Glad to say I found the problem so ill pass it on.

I pulled the 5 month old Alt out today and when I spun it I could here a clicking noise. So I grabbed my 7 year old Alt that had intermittent light no charge issue and it didn't make any clicking noise. I thought maybe brush noise. So I pulled the guts off the new alt and put in on the old one put it all back together and BAM no more lights. I checked charging is fine at 14.23. I also found out why the old alt had issue the brushes were so worn they we not hitting the armature.
I found that out when I went to put the new assembly on I had to push the brushes in to get them on the armature. So I looked at the old one they were worn so bad the barley came out of the housing.

Not sure if you can buy brushes only but if you can people might think they got bad alt and it might be brushes only. I will mention I have 324,873 Miles on my Yaris.

Take Care Everyone

Great news! Thanks for the update. Follow up is so important and will no doubt help someone else in the future.

I had torn the alternator from my '06 apart and did think about replacing the voltage regulator, brushes etc but decided to go for a reman instead. It's much more satisfying when you fix a component as opposed to replacing it.