Alternator: Service and Repair

REMOVAL
1. Remove the air cleaner lid, disconnect the inlet air sensor and makeup air hose.
2. Disconnect the negative battery cable.

Fig. 7 Generator T-Bolt Locknut And Adjustment Bolt:

3. Loosen the upper generator T-bolt lock nut.
4. Raise vehicle on hoist.
5. Remove the right front wheel.

Fig. 8 Accessory Drive Splash Shield:

6. Remove the accessory drive splash shield.

Fig. 9 Pencil Strut:

7. Remove the pencil strut.

Fig. 10 Lower Pivot Bolt:

8. Loosen the lower pivot bolt.
9. Loosen the accessory drive belt t-bolt.

Fig. 11 Battery Connection:

10. Unplug field circuit from generator.
11. Remove the B+ terminal nut and wire.
12. Remove the generator belt, refer to the Cooling section for more information.
13. Remove the axle retaining nut.
14. Remove the lower control arm from steering knuckle.
15. Remove axle shaft. Put a container under the transmission to catch the transmission fluid from the transmission.
16. Remove the generator lower mounting bolt and nut from the upper T-bolt.

Fig. 12 Generator Removal:

17. Remove generator out the bottom.

INSTALLATION
1. Install generator and loose assemble the bolt and nut.
2. Install and tension the generator belt, refer to the Cooling section for more information.
3. Tighten the lower pivot bolt to 54 Nm (40 ft.lbs.)
4. Install axle shaft, refer to the Axle section
5. Install lower control arm to steering knuckle, refer to the Suspension section.
6. Install the lower ball joint nut and tighten
7. Install the axle retaining nut and tighten, refer to the Axle section.
8. Install the pencil strut, refer to the body section.
9. Install the B+ terminal nut and wire and tighten to 11.3 Nm (100 in. lbs.).
10. Plug in the field circuit to the generator
11. Install the accessory drive splash shield.
12. Install the right front wheel.
13. Lower vehicle.
14. Tighten the T-bolt locknut and tighten to 54 Nm (40 ft. lbs.)
15. Connect the negative battery cable.
16. Install the air cleaner lid and connect the inlet air temperature sensor and makeup hose.
17. Check the transmission fluid.