Remove the end cover (A) and the terminal insulator (B).
4.
Brush Holder Assembly - Remove
Remove the brush holder assembly (A).
5.
Rear Housing Assembly - Remove
Remove the rear housing assembly (A) and the washer (B).
6.
Rotor and Drive-End Housing - Remove
1.
Remove the rotor from the drive-end housing.
2.
Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.
If the rotor is damaged, replace the rotor assembly.
7.
Front Bearing Retainer - Remove
Remove the front bearing retainer.
8.
Front Bearing - Remove
Drive out the front bearing with a brass drift and a hammer.
9.
Brush - Inspect
Measure the length of both brushes (A) with a vernier caliper (B).
If either brush is shorter than the service limit, replace the brush holder assembly.
Alternator Brush Length
Standard (New):
10.5 mm (0.413 in)
Service Limit:
1.5 mm (0.059 in)
10.
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.
NOTE: Refer to the Exploded View if needed during this procedure.
1.
Front Bearing - Install
Use a hand press to install the new front bearing (A) in the drive-end housing, with the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.
2.
Front Bearing Retainer - Install
Install the front bearing retainer.
3.
Rotor and Drive-End Housing - Install
Install the rotor to the drive-end housing.
4.
Rear Housing Assembly - Install
Install the rear housing assembly (A) and the washer (B).
5.
Brush Holder Assembly - Install
1.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.
2.
Install the brush holder.
3.
Install the brush holder assembly.
4.
Pull out the pin or drill bit.
6.
End Cover and Terminal Insulator - Install
1.
Install the terminal insulator (A) and the end cover (B).
