How to Rebuild an Associated Style Rectifier with a 696610 Rebuild Kit

Battery chargers take a beating over time, especially when they’re used for heavy-duty jump-starting and daily shop work.

In this video, we walk through the complete process of restoring an Associated style rectifier using the PLP Battery 696610 rebuild kit. From cleaning the heat sink plate to installing new button diodes and testing the finished assembly, this step-by-step guide helps you bring an old charger back to life while saving money on replacement parts.

Key Takeaways from the Rebuild

• Learn how an associated style rectifier converts AC power to DC power for battery charging

• Identify common signs of rectifier failure, including burned diodes and damaged contactors

• See how to properly clean and prepare the original rectifier plate

• Understand the purpose of thermal grease and why it improves heat transfer

• Follow a complete step-by-step rebuild process using the 696 610 kit

• Learn how to test diode orientation and functionality using a multimeter

• Discover how proper charger use and duty cycles help prevent future failures

Inside the Rebuild Process

To begin, inspect the old rectifier plate for heat damage, debris, and burned components. A clean mounting surface is critical because the button diodes rely on direct metal contact for cooling and electrical performance.

The 696 610 rebuild kit includes everything needed for the restoration, including:

• Button diodes

• Spoked contactors

• O-rings

• Washers and insulated spacers

• Caps and hardware

• Thermal grease

One of the most important parts of the rebuild is applying thermal grease to the diode mounting surfaces. This helps eliminate tiny air gaps between the diode and plate, improving heat dissipation and extending component life.

During assembly, install button diodes with the painted ring side facing downward. Carefully center the spoked contactors over the diodes before tightening the hardware. Proper alignment is essential because these contactors act as sacrificial protection during electrical overloads.

Once assembled, the rectifier should be tested with a multimeter to verify correct diode orientation and operation. A properly installed diode will conduct in one direction and block current in the opposite direction.

One of the biggest causes of rectifier damage is overloading the charger during jump-starting. Ignoring recommended duty cycles can quickly overheat and destroy the rectifier assembly.

Why Rebuilding Makes Sense

Rebuilding an Associated style rectifier is often far more cost-effective than replacing the entire charger or purchasing a new rectifier assembly. It also helps extend the life of older equipment while reducing unnecessary waste.

For technicians, shop owners, and DIY mechanics, learning this rebuild process can save both time and money while keeping chargers operating reliably.

Watch the Full Rebuild and Get Your Charger Back in Service

If your charger is showing signs of rectifier failure, this rebuild walkthrough will help you confidently tackle the repair yourself. Follow along step-by-step, use the proper thermal protection methods, and test your assembly carefully before returning the charger to service.

For rebuild kits, replacement parts, or additional support, contact PLP Battery Supply or call 800-642-3451.