Disassembly and Reassembly

Alternator Overhaul

Charging System - Alternator Overhaul:

Exploded View

Special Tools Required
- Handle Driver 07749-0010000
- Attachment, 52 x 55 mm 07746-0010400

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

1. Test the alternator and regulator before you remove them.
2. Remove the alternator.




3. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.




4. Remove the three flange nuts and the insulator from the alternator.




5. Remove the end cover (A) and seal ring (B).




6. Remove the brush holder (A) and seal ring (B).




7. Remove the four bolts, then remove the rear housing assembly (A), washer (B), and rear bearing cover (C).




8. If you are not replacing the front bearing and/or rear bearing, go to step 15. Remove the rotor from the drive end housing.
9. 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
- If the rotor is OK, go to step 10




10. Remove the rear bearing using a puller as shown.




11. With a hammer and commercially available tools shown, install a new rear bearing in the rotor shaft.




12. Remove the front bearing retainer plate.




13. Drive out the front bearing with a brass drift and hammer.




14. With a hammer and special tools, install a new front bearing in the drive end housing.

Alternator Brush Inspection




15. Measure the length of both brushes (A) with vernier calipers (B).
- If either brush is shorter than the service limit, replace the brush holder assembly.
- If brush length is OK, go to step 16.

Rotor Slip Ring Test




16. Check that there is continuity between the slip rings (A).
- If there is continuity, go to step 17.
- If there is no continuity, replace the rotor assembly.

17. Check that there is no continuity between each slip ring and the rotor (B) and the rotor shaft (C).
- If there is no continuity, replace the rear housing assembly, and go to step 18.
- If there is continuity, replace the rotor assembly.

18. Assemble the alternator in reverse order of disassembly, and note these items:
- Be careful not to get any grease or oil on the slip rings.
- If you removed the pulley, tighten its locknut to 111 N.m (11.3 kgf.m, 81.7 lbf.ft) when you reinstall it.