Melting back on my voltage regulator. Have you seen this before?

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cruiser

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Hi All: Just this afternoon I noticed something that caught my eye. It appears that the gooey black stuff on the back of my NOS voltage regulator is running down the inner fender. My 1974 Duster is completely stock electrically. No modifications whatsoever. The voltage regulator was a date coded NOS unit when I bought it about four years ago. Everything runs well - that is, for a 51 year old car (headlights dim a bit when stopped at a red light, etc.). The runny part is pretty small. Have you seen this before, and is it evidence of an impending voltage regulator failure? If I need to get a new regulator, which one would you recommend? I'd like to keep it really stock looking. Ideas?

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Yeah that's what they do when they over heat and melt the goo out of the back. That usually means they are on the way out.
 
I have had it happen on these stored in the garage. So the overheating when going bad idea is baloney.

One guy talked about putting a plate behind the unit the same shape with a thin gasket or sealer around the edge to keep dirt and water out. That seems like what the goo is for.
 
In my experience, the pottent used on electronics especially old electronics falls apart over time. Heat accelerates the process.

I have seen foam tape that turned to grease after 25 years.
 
I was gonna say it might be due to engine bay temps, but if its beem there 4 years...


Al, I was tempted, but the $15 in shipping is outta my budget. :lol:
I agree, I was ready to pull the trigger on all of them but shipping is a little steep.
 
Cruiser, that is very common. Seen it a million times on running cars. I agree that the material just breaks down over time. I have cleaned the goo off on my own Car in the past and just kept running the car without issue. They make a Mopar restoration one that looks pretty close to the original-black with a sticker used for the numbers.
 
I can re pot the back of that if needed? with a skim coat of new potting that will not fail. Personally, I would not dig into it to get the old out might hit a component. I have it for ECU's. Seen that many times TF360 is spot on
 
The material you see is a potting compound. It is not melting, but is slowly breaking down and oozing out. Potting compound has been used for decades in electronics to seal for environmental protection against moisture, debris, etc. and movement of internal components from vibration, mechanical shock, etc. The compounds are typically fast curing two part or single component chemicals that form a solid or semi-solid protective barrier. Over time the compound can break down and "run" or otherwise deteriorate. Heat does not necessarily cause it, but can aggravate the breakdown.

Chrysler used semi-solid potting compounds in the electronic control units (ECUs), electronic voltage regulators, air conditioning high speed cutout controllers, EGR timers, and other similar electronic modules. In some ECUs and voltage regulators, sand was added to the compound as an additional stiffener for mechanical shock and vibration resistance.

1970s assemblies are more susceptible than later production parts. Later production was changed to a more rubber like compound that breaks down less. In general, the parts will continue to function with the compound leaking out unless affected by moisture or other factors. Aftermarket components can also suffer from similar breakdown depending on the nature of their compound.

When the early compound used by Chrysler runs it forms a sticky mess. It can be dissolved with lacquer thinner, but it's tricky to remove from painted surfaces without risking the paint. I've successfully removed it with lacquer thinner from vehicles as well as ECUs and voltage regulators, including the internal areas. Removal from the internal areas does risk removing electronic component markings and weakening the components, especially the electrolytic capacitors. I have replaced the removed potting compound with two part (A-B) silicone or urethane compounds.
 
Clean it up, repot if you want, and don't worry about it. I've had brand new ones in their sealed box sitting on a shelf do that in a climate controlled garage. As long as the components are still coated for moisture protection, they'll work just fine.
 
ECU's are a PIA, had a chance to get a few hundred Mopar orange ones, but all glued together, had to pass, too much work for 20 each profit. Regret it now with them over a buck each.
 
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