Disassembly

Generator Assembly:

REMOVE OR DISCONNECT
TOOL REQUIRED:
J 22912-01 Bearing Remover

Generator Housing Matchmarks:

1. Scribe matchmarks on the front and rear housing to ensure proper assembly.

Generator Housing Bolts:

2. Four generator housing bolts from front housing.

Removing Front Housing (with Drive Pulley And Rotor):

3. Using a flat-bladed tool, gently pry off the front housing (with drive pulley and rotor) from the stator coil and rear housing.
4. Place the front housing and rotor into a vise, facing the drive pulley up.

NOTE: To prevent damage to the rotor, place clean shop cloths between the rotor and vise.

5. Drive pulley retaining nut.
6. Drive pulley washer and drive pulley from rotor.
7. Front housing and rotor from vise.
8. Rotor and spacer from front housing.

Front Bearing Retainer Screws:

9. Four screws, front bearing retainer and front bearing from front housing.

Removing Front Housing (with Drive Pulley And Rotor):

10. Rear bearing from rotor using a J 22912-01 and a press.

Battery Terminal Retaining Nut:

11. Battery terminal retaining nut from rear housing.
12. Stator leads from rectifier using a soldering iron.

Stator Retaining Screws:

13. Four retaining screws and stator from rear housing.
14. One nut and rectifier from rear housing.
15. Regulator and brush holder from rear housing.
16. Brush holder from regulator

Removing Brushes From Regulator:

17. Brushes from regulator.
A. Remove brush lead wire cover.
B. Using a soldering iron, heat and disconnect brush lead wires from regulator terminals.
C. Remove brushes and brush springs from regulator.