Disassembly and Assembly

Figure 12:

Disassembly

NOTE: All of the following disassembly steps may not be necessary to perform a particular test or service. Perform only those steps that apply in your case. See Figure 12 for a full disassembled view of the integral alternator/ regulator assembly. On alternators with fan shield, remove attaching clip and then remove fan shield.
1. Remove the four screws (T20 TORX type head) attaching the regulator to the alternator rear housing. Remove the regulator, with brush holder attached, from the alternator.

2. Remove the two screws (T20 TORX type head) attaching the regulator to the brush holder. Separate the regulator, attaching nuts, brushes and brush springs from the brush holder.

3. Scribe a line across the end housings and stator laminated core for reference during assembly.

4. Remove the three through bolts.

5. Separate the front housing and rotor assembly from the stator and rear housing. It may be necessary to tap the front housing with a plastic tipped hammer to loosen the front housing from the stator core.
6. Remove the three stator lead terminals from the rectifier. Unsolder the connections using a 100 watt soldering iron. Do not allow the soldering iron to overheat the rectifier. Use a needle nose plier to pull the stator lead terminals upwards from the rectifier assembly. Separate the stator from the rear housing.

7. Remove the four rectifier assembly attaching screws (T20 TORX type head) and remove the rectifier assembly from the housing.

8. Using a suitable arbor press, remove the bearing from the rear housing. Support the housing close to the bearing boss to prevent housing damage.

Figure 11:

9. Clamp the front housing in a vise with protective jaws (Figure 11).

10. Remove the drive pulley retaining nut from the rotor using removal and installation tool, T65P- 10300-B or equivalent (Figure 11).

11. Remove the flat washer, drive pulley, fan and fan spacer from the rotor shaft.

12. Remove the rotor from the housing and remove the housing from the vise.

13. Remove the front rotor stop from the rotor shaft. Do not remove the stop ring from the rotor shaft unless it is damaged.

14. Remove the screws attaching the bearing retainer to the front housing and remove the retainer.

15. Remove the bearing from the front housing. If the bearing will not slide out, remove it using a suitable arbor press. Support the bearing close to the bearing boss to prevent damage to the housing.