Generator Overhaul

DISASSEMBLY PROCEDURE

Generator Overhaul: Disassembly Procedure:

Only the following generator components are serviceable:
^ The pulley (3)
^ The front bearing
^ The regulator
^ The rear cooling duct
If any of the following components need replacement, replace the generator:
^ The rear bearing
^ The rectifier bridge
^ The armature
^ The field coil

Tools Required
^ J 42072 Rear Brake Backing Plate Bolt Remover
^ J 35669 Strut Rod Nut Remover and Installer

1. Remove the generator.
2. Hold the generator shaft using the J 42072 while loosening the pulley nut using the J 35669.
3. Remove the following pulley components:
^ The nut
^ The washer
^ The pulley
^ The spacer




4. Remove the cooling duct cap:
^ Remove the screws (2).
^ Remove the cap (1).




5. Remove the voltage regulator:
^ Remove the regulator screw (2).
^ Remove the regulator (1).




6. Remove the housing bolts (2).
7. Separate the generator housing. (The armature will remain with the front half of the housing.)




8. Remove the armature from the housing:
^ Support the generator housing.
^ Lightly tap on the armature shaft using a soft mallet in order to separate from the housing.
9. Remove the front bearing screws (1).
10. Remove the front bearing retainer (4).
11. Remove the front bearing (3) from the housing (2).

ASSEMBLY PROCEDURE



1. Press the front bearing to the housing using a suitable size piece of pipe or a socket.
2. Install the front bearing retainer (4).
3. Install the front bearing screws (1).
4. Install the armature to the housing (2):
^ Support the armature.
^ Lightly tap on the housing in order to seat the armature.




5. Connect the generator housing.
6. Install the generator housing bolts (2).

NOTE: Refer to Fastener Notice in Cautions and Notices.

Tighten
Tighten the bolts to 5 N.m (44 lb in).




7. Install the voltage regulator:
^ Position the regulator (1).
^ Install the screws (2).

Tighten
Tighten the screws to 1.5 N.m (13 lb in).




8. Install the cooling duct cap:
^ Position the cap (1).
^ Install the screws (2).

Tighten
Tighten the screws to 1 N.m (9 lb in).

Generator Overhaul: Disassembly Procedure:

9. Install the following pulley components:
^ The spacer (4)
^ The pulley (3)
^ The washer (2) with the beveled side toward the generator
^ The nut (1)

10. Hold the generator shaft using the J 42072 while tightening the nut using the J 35669.

Tighten
Tighten the screws to 65 N.m (48 lb ft).

11. Install the generator.