Alternator Overhaul
Special Tools Required
Image Description/Tool Number
310169.png Driver Handle, 15 x 135L 07749-0010000
310160.png Bearing Driver Attachment, 42 x 47 mm 07746-0010300
1. Alternator - Exploded View

Exploded View



NOTE: Refer to the Exploded View if needed during this procedure.

1. Terminal Insulator and Bracket - Remove

2. Cover - Remove

3. Brush Holder/Regulator - Remove
1.
Remove the brush Holder (A), then remove the regulator (B).

4. Stator Assembly - Separate
1.
Remove the four through bolts.






Properly installed:

Improperly installed:
2.
Separate the front housing (A) from the stator core (B) by inserting a flat-tip screwdriver into the openings and prying them apart.
NOTE:
Be careful not to damage the stator coil with the tip of the screwdriver.
Do not remove the bearing holder (C) from the stator assembly (D). If the bearing holder is not installed properly, replace the stator as assembly.

5. Brush - Inspect
1.
Measure the length of both brushes with a vernier caliper. If either brush is shorter than the service limit, replace the brushes.
Alternator Brush Length
Standard (New):
14 mm (0.55 in)
Service Limit:
4.5 mm (0.177 in)

6. Pulley - Remove
1.
Clamp the rotor in a soft-jawed vise.
2.

3.
Without OAD: Remove the pulley nut, then remove the pulley.

7. 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 no continuity, replace the rear housing assembly.
If there is continuity, replace the rotor assembly.

8. Spacer Ring/Front Bearing Retainer - Remove

9. Front Bearing - Install
1.
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.
Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L, and the attachment, 42 x 47 mm.

2. Spacer Ring/Front Bearing Retainer - Install

3. Pulley - Install
1.
Install the front housing and the rotor.
2.

3.
Without OAD: Clamp the rotor in a soft-jawed vise, then tighten the pulley lock nut.

4. Stator Assembly - Install


Properly installed:

Improperly installed:
1.
Install the front housing (A) and the stator assembly (B).
NOTE: Do not remove the bearing holder (C) from the stator assembly (D). If the bearing holder is not installed properly, replace the stator as assembly.
2.
Install the four through bolts.

5. Brush Holder/Regulator - Install
1.
Install the regulator (A), then install the brush Holder (B).

6. Cover - Install

7. Terminal Insulator and Bracket - Install