How to Maintain a Voltage Regulator on Dodge Sprinter 2500?

First, take off the negative battery cable to stay safe while working on the regulator. Secure and raise your vehicle, then taking out bolt 2 at the turbocharger brace 1. Unbolt bolt 1 from brace 2 and turn the swivel so it is on the side. Go ahead and take out screws 3 and 4, then remove wires 5 and 6. Lift off the cover over source 1 by undoing screw 2 and nuts 3 and 4. Unscrew parts 1, 3 and 4, then take out the voltage regulator 2 by pulling it out directly from the generator. If the condition of the commutator rings 1 is worn, you should replace the whole generator assembly. If the carbon brushes 1 seem worn, you may likely need to replace the generator assembly too. Before installation, ensure the carbon brushes 1 and commutator rings 1 are not badly worn. Attach voltage regulator 2 at the back of the generator and line it up before installing it slowly into the generator. Once screws 1, 3 and 4 are in, notch fit cover 1 back in place with screw 2 and nuts 3 and 4. Put eyelets 5 and 6 next to the generator studs and tighten on the + terminal screws, BUT, ONLY use the included nut 4, attached to the + terminal and tighten it to 18 N.m (159 in. lbs.) and nut 3 instead. First, place and tighten brace bolt 1 into brace 2 to 20 N.m (15 ft. lbs.), then install bolt 2 into turbocharger brace 1 and tighten it to 30 N.m (22 ft. lbs.). Drop the car, fasten the negative battery cable and make sure the charging system runs as expected.

OEM Dodge Voltage Regulator

Adjustable Voltage Regulator

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Dodge Voltage Regulator Part Number: 5234625
$92.66 MSRP: $141.00
You Save: $48.34 (35%)
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Product Specifications
- Other Name: Regulator - Alternator Voltage; Regulator; Voltage Regulator , (Use Mounting Screw 6034261) Europe; Regulator, Voltage
Fits the following Dodge Models:
- 600 | 1984-1988 | Base, ES, SE | 4 Cyl 2.2 L GAS, 4 Cyl 2.5 L GAS, 4 Cyl 2.6 L GAS
- Aries | 1984-1989 | America, Base, Custom, LE, SE | 4 Cyl 2.2 L GAS, 4 Cyl 2.5 L GAS, 4 Cyl 2.6 L GAS
- B150 | 1984-1990 | Base | 6 Cyl 3.7 L GAS, 6 Cyl 3.9 L GAS, 8 Cyl 5.2 L GAS
- B250 | 1984-1990 | Base | 6 Cyl 3.7 L GAS, 6 Cyl 3.9 L GAS, 8 Cyl 5.2 L GAS, 8 Cyl 5.9 L GAS
- B350 | 1984-1990 | Base | 8 Cyl 5.2 L GAS, 8 Cyl 5.9 L GAS
- Caravan | 1984-1989 | Base, C/V, LE, SE | 4 Cyl 2.2 L GAS, 4 Cyl 2.5 L GAS, 4 Cyl 2.6 L GAS, 6 Cyl 3.0 L GAS
- Charger | 1984-1987 | 2.2, Base, Shelby | 4 Cyl 1.6 L GAS, 4 Cyl 2.2 L GAS
- D100 | 1985-1989 | Custom | 6 Cyl 3.7 L GAS, 6 Cyl 3.9 L GAS, 8 Cyl 5.2 L GAS, 8 Cyl 5.9 L GAS
- D150 | 1984-1993 | Base, S | 6 Cyl 3.7 L GAS, 6 Cyl 3.9 L GAS, 8 Cyl 5.2 L GAS, 8 Cyl 5.9 L GAS
- D250 | 1984-1993 | Base | 6 Cyl 3.7 L GAS, 6 Cyl 3.9 L GAS, 6 Cyl 5.9 L DIESEL, 8 Cyl 5.2 L GAS, 8 Cyl 5.9 L GAS
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Dodge Regulator Part Number: 68078956AA
$95.40 MSRP: $143.00
You Save: $47.60 (34%)
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Product Specifications
- Other Name: Regulator - Alternator; Voltage Regulator; Regulator Alternator
- Replaces: 5183842AA, 5135837AA
Fits the following Dodge Models:
- Sprinter 2500 | 2004-2006 | Base | 2.7L L5, 5 Cyl 2.7 L DIESEL
- Sprinter 3500 | 2004-2006 | Base | 2.7L L5, 5 Cyl 2.7 L DIESEL
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Dodge Regulator Part Number: 5133774AA
Product Specifications
- Other Name: Regulator - Alternator; Voltage Regulator; Regulator Alternator
Fits the following Dodge Models:
- Sprinter 2500 | 2003-2004 | Base | 5 Cyl 2.7 L DIESEL
- Sprinter 3500 | 2003-2004 | Base | 5 Cyl 2.7 L DIESEL

Dodge Voltage Regulator

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Dodge Voltage Regulator maintains the current at a constant rate, ensuring the battery life as well as supplying all onboard systems with energy. Raw strength has been pursued by Dodge since the first all-steel body debuted in 1914, combining tough frames and HEMI muscle, Viper born track urgency, and the new Fratzonic Chambered Exhaust that whispers or shouts at will, yet lets drivers feel unashamed power without compromising either choice or attitude. Dodge does not do boring rides, and every lineup is filled with aggressive lines, bright colors and driving modes that swing like a Donut fun to Drag aggression, and the readiness of the brand to install a 600 watt sound system on an electric platform is an indication that it believes in excitement over words on paper. Dodge uses the Voltage Regulator to smooth the raw surge of the alternator that occurs immediately after high revolutions due to the Voltage Regulator sensing battery feedback in milliseconds, adjusting field current, stabilizing output at an ideal 13.5 to 14.5 volts and replacing crudely mechanical guts with a small high speed solid state switch resistant to road shake. Dodge has confidence in this Voltage Regulator throughout the product range, as when the Voltage Regulator is connected to charge the battery based on battery temperature and engine load, flicker-free headlights, no speaker distortion, infotainment memory protection and quiet confident driver performance is achieved at the expense of glitzy warning lights.

Dodge Voltage Regulator Parts and Q&A

Regulator
68078956AA
Q: How to Maintain a Voltage Regulator on Dodge Sprinter 2500?
A:
First, take off the negative battery cable to stay safe while working on the regulator. Secure and raise your vehicle, then taking out bolt 2 at the turbocharger brace 1. Unbolt bolt 1 from brace 2 and turn the swivel so it is on the side. Go ahead and take out screws 3 and 4, then remove wires 5 and 6. Lift off the cover over source 1 by undoing screw 2 and nuts 3 and 4. Unscrew parts 1, 3 and 4, then take out the voltage regulator 2 by pulling it out directly from the generator. If the condition of the commutator rings 1 is worn, you should replace the whole generator assembly. If the carbon brushes 1 seem worn, you may likely need to replace the generator assembly too. Before installation, ensure the carbon brushes 1 and commutator rings 1 are not badly worn. Attach voltage regulator 2 at the back of the generator and line it up before installing it slowly into the generator. Once screws 1, 3 and 4 are in, notch fit cover 1 back in place with screw 2 and nuts 3 and 4. Put eyelets 5 and 6 next to the generator studs and tighten on the + terminal screws, BUT, ONLY use the included nut 4, attached to the + terminal and tighten it to 18 N.m (159 in. lbs.) and nut 3 instead. First, place and tighten brace bolt 1 into brace 2 to 20 N.m (15 ft. lbs.), then install bolt 2 into turbocharger brace 1 and tighten it to 30 N.m (22 ft. lbs.). Drop the car, fasten the negative battery cable and make sure the charging system runs as expected.