Remove the heat shield (A) and the harness brackets (B).
3.
Terminal Insulator - Remove
Remove the terminal insulator (A).
4.
Rear Housing - Remove
1.
Remove the four through bolts.
2.
Heat the rear bearing seat with a heat gun for about 5 minutes (122?140 °F (50?60 °C)).
3.
Separate the rear housing from the drive-end housing by inserting a flat-tip screwdriver into the openings and prying them apart.
NOTE: Be careful not to damage the stator with the tip of the screwdriver.
4.
Separate the rear housing (A) and the drive-end housing (B) with the stator (C) attached to the rear housing.
5.
Stator - Remove
Remove the stator.
6.
Stator - Inspect
1.
Check for continuity between each lead (A).
If there is no continuity, replace the stator.
2.
Check for continuity between each lead and the coil core (B).
If there is continuity, replace the stator.
7.
Voltage Regulator/Brush Holder Assembly - Remove
Remove the voltage regulator/brush holder assembly (A).
8.
Brush - Inspect
1.
Check the service limit line (A) of both brushes:
If the service limit line of either brush is not visible due to brush wear, replace the brushes.
If the brush length is OK, go to step 2
2.
Remove the cover (A).
3.
Unsolder the brush leads from the voltage regulator/brush holder assembly with a 100 W soldering iron (B), then replace the brushes.
9.
Rectifier - Remove
Remove the rectifier.
10.
Rectifier - Inspect
Stator side
Rear housing side
Check for continuity in each direction, between the B terminal and P terminals, and between the E terminal and P terminals of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of six diodes (six pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 24 checks.
If any diode fails, replace the rectifier assembly. (Diodes are not available separately.)
11.
Rotor - Remove
1.
Remove the rotor.
2.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.
NOTE: If either the rotor or drive-end housing is damaged, replace the alternator.
12.
Rotor Slip Ring - Test
1.
Check for continuity between the slip rings (A).
If there is continuity, go to step 2.
If there is no continuity, replace the rotor assembly.
2.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
If there is continuity, replace the rotor assembly.
If there is no continuity, replace the rear housing assembly.
If there is continuity, replace the rotor assembly.
13.
Rear Bearing - Remove
Remove the rear bearing using the puller as shown.
14.
Front Bearing - Remove
1.
Remove the front bearing retainer.
2.
Drive out the front bearing with a brass drift and a hammer.
NOTE: Refer to the Exploded View if needed during this procedure.
1.
Front Bearing - Install
1.
Use a hand press to install a new front bearing (A) in the drive-end housing, with the driver handle, 15 x 135L, and the attachment, 42 x 47 mm.
2.
Install the front bearing retainer.
2.
Rear Bearing - Install
Use a hand press to install the new rear bearing (A). Apply pressure only on the inner race to avoid damaging the bearing.
3.
Rotor - Install
Install the rotor.
4.
Rectifier - Install
Install the rectifier.
5.
Voltage Regulator/Brush Holder Assembly - Install
Install the voltage regulator/brush holder assembly (A).
6.
Stator - Install
Install the stator.
7.
Rear Housing - Install
1.
Remove any grease or oil from the slip rings.
2.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (1/16 in) diameter) to hold them in place.
3.
Heat the rear bearing seat with a heat gun for about 5 minutes (122?140 °F (50?60 °C)).
4.
Put the rear housing assembly (A) and the drive-end housing/rotor assembly (B) together, tighten the four through bolts (C), and pull out the pin (D).
5.
After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise.
8.
Terminal Insulator - Install
Install the terminal insulator (A).
9.
Heat Shield - Install
Install the heat shield (A) and the harness brackets (B).
