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Bench Testing: Rotor

WARNING: This page is about a different car, the 2001 Audi allroad, 2001 Audi S4, 2001 Audi A6, and 2001 Audi A4. However, it is still accessible from the selected car via links, so may be relevant.
  1. Set ohmmeter on lowest scale. Connect ohmmeter leads between slip rings. If resistance is less than 2.8 ohms, rotor windings are shorted. Replace rotor. If resistance is greater than 3.1 ohms, high resistance exists in rotor windings. Replace rotor.
  2. Set ohmmeter on 1000x scale. Connect ohmmeter leads between either slip ring and rotor. If continuity exists, rotor is grounded. Replace rotor.
  3. Clean slip rings using sandpaper. If rings are worn or pitted, turn them on lathe. Minimum slip ring diameter is 1-1/16" (27 mm).
  4. If slip rings cannot be repaired, remove rear bearing from slip ring end of rotor. Unsolder wires from slip rings. Bend up ends of rotor winding. Pull off slip rings. Ensure ends of rotor winding are not damaged.
  5. Insert ends of rotor winding into slip ring, and press new slip ring onto rotor until slip ring end is 9/64" (3.57 mm) from end of collar. Solder rotor winding to slip ring terminals. Turn rings on lathe, and retest rotor. Maximum slip ring runout is .0012" (.03 mm).
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