Inside the Workshop: Weekly Remanufacturing Spotlight

At DFJ Automotive we specialise in the remanufacture & rebuild of starter motors, alternators & many more machinery parts.

Take a look at this week’s remanufacturing work, where worn components are carefully restored back to reliable, high-performance condition.

Rebuild Journal 1

Rebuild of the Week – DFJ020441🔧

This week, we’re shining the spotlight on a true workhorse of vintage engineering — the DFJ020441, a professionally reconditioned Lucas LRS00105 / 26172 M45G lever starter motor. Built with precision and reliability in mind, this unit is ready to bring classic machinery back to life ⚙️

⚙️ Key Specifications

✅ 12 Volts

✅ 11 Teeth

✅ Clockwise Rotation

Designed to deliver dependable starting power, this starter motor is an ideal match for some of the most iconic Fordson diesel tractors ever built.

🚜 Perfect Fit For:

Fordson New Major

Fordson Power Major

Fordson Super Major

Rebuild Journal 2

Rebuild of the Week – DFJ010595🔧

This week’s spotlight is on the DFJ010595, a reconditioned Butec 851353 Alternator of an E-Type Jaguar⚙️

⚙️ Key Specifications

✅12 Volts
✅60 Amp
✅Clockwise rotation
✅Cradle mount
✅External Fan

Commonly fitted to these E Type Jaguars:
🛞 Jaguar E-Type / XKE models
🛞 Series 3 V12 E-Type / XKE models (1971-1975)

Rebuild Journal 3

Rebuild of the Week – DFJ010636🔧

This week’s spotlight is on the DFJ010636, a reconditioned Lucas 23521 / TRIUMPH 215167 Alternator of an E-Type Jaguar⚙️

⚙️ Key Specifications

✅12 Volts
✅36 Amp
✅Clockwise rotation
✅Lug mount
✅External Fan

Commonly fitted to these E Type Jaguars:
🛞 Jaguar E‑Type Series 2
🛞1971-2 Triumph Stag

Rebuild Journal 4

Rebuild of the Week – DFJ020153🔧

This week’s spotlight is on the DFJ020153, a reconditioned Bosch 0001-601-028. This starter motor is of a heavy-duty industrial/ gas/diesel generator/ large engine application⚙️

⚙️ Key Specifications

✅24 Volts
✅17 Tooth
✅Clockwise rotation
✅15 Kilowatt (kW)
✅Co-Axial

Commonly fitted to these applications:
⚙️TBG 620 V20, TCG 2020 V20
⚙️Jenbacherwerkeag (120345)
⚙️Deutz (1230740) (1301737) (15025488)
⚙️ MWM (305720100016)
⚙️Bosch (0001601028)

Rebuild Journal 5

Rebuild of the Week – Bosch 0120489541 Alternator🔧

This week’s rebuild spotlight features the Bosch 0120489541 alternator, recently sent in by a customer from his classic Ferrari 308. ⚙️

This iconic unit has been fully reconditioned to factory specifications, ensuring the same precision and performance that made it legendary.

⚙️ Key Specifications

✅ 12 Volts
✅ 55 Amps
✅ Clockwise Rotation
✅ External Fan
✅ Lug Mount

At our workshop, we specialize in reconditioning genuine Bosch alternators using 100% original components — restoring each unit to as-new reliability and performance.

Rebuild Journal 6

Rebuild of the Week – Bosch 0120489541 Alternator🔧

This 24V DC motor just came in from one of our customers for a full rebuild and reconditioning. These motors are the heart of many lifting systems — from hydraulic power units to scissor lifts — and keeping them in top shape is critical.

Rebuild Journal 7

Rebuild of the Week – Niehoff C653A Alternator🔧

Take a look behind the scenes at DFJ Automotive LTD as we bring another heavy-duty unit back to life. In this video, our team works through the remanufacturing of a Niehoff C653A alternator — a powerful 24V, 260-amp unit designed for demanding applications.

This particular alternator features bi-directional rotation (CW & ACW) and an external cooling fan, making it a robust and versatile component in specialist vehicle systems.

From inspection and strip-down to precision rebuilding and testing using our expert technical knowledge, this short glimpse highlights the care, expertise, and attention to detail that goes into every remanufactured unit we produce.

At DFJ Automotive LTD, quality remanufacturing helps extend component life, maintain reliability, and support sustainable engineering practices.

▶️ Watch the process and see how we keep critical systems running through the link below.

Niehoff C653A Remanufacture video

Rebuild Journal 8

Rebuild of the Week – Bosch 0001-601-007 Starter Motor 🔧

Heavy-duty? That’s where we shine 💪

Watch the remanufacturing process of a Bosch 0001-601-007 below— brought back to life with precision, expertise, and over 32 years of hands-on experience.

Remanufacturing Journey of Bosch 0001-601-007 Series

At the core of what we do:
✔️ Complete strip, inspection & rebuild
✔️ High-quality components only
✔️ Built to perform under pressure

We don’t just repair — we recondition to OEM-level standards, especially for heavy-duty applications.

Rebuild Journal 9

Rebuild of the Week – Inside our workshop / CAV AC7 rebuild 🔧

In this week’s feature, we take you behind the scenes of our workshop process:

• The journey begins with our core stock — a carefully sourced selection of units ready for reconditioning. Each one is inspected and assessed for rebuild potential.
• From there, we move into the detailed stages of remanufacturing, showcased here through a recent rebuild of a CAV AC7 alternator.
• Every component is stripped, cleaned, tested, and rebuilt with care to ensure it meets original performance standards.

This transformation process highlights not just the technical work involved, but the craftsmanship behind every unit we produce.

🛠️ Over 30 Years of Expertise

With more than three decades of industry experience, we’re proud to be among the UK’s remaining specialist remanufacturers. Our reputation is built on:

⚙️ Expert reconditioning

⚙️ Trusted, time-served knowledge

⚙️ Components built to last