Alternator Overhaul
Special Tools Required
Image Description/Tool Number
310169.png Driver Handle, 15 x 135L 07749-0010000
310160.png Bearing Driver Attachment, 42 x 47 mm 07746-0010300

NOTE: enu_12713377_2.0 Where icon is shown, click for further information.


1


1828_3.0_enu_14740956_5.0

enu_12713377_2.0
Detailed information, notes, and precautions
enu_12714524_1.0
Replace
*1
These parts have inspection items.

2. Heat Shield - Remove


3. End Cover - Remove


4. Terminal Insulator - Remove


5. Brush Holder - Remove


6. Stator Assembly - Remove


7. Bearing Holder - Remove


8. Rotor - Remove

NOTE: 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.

9. Front Bearing Retainer - Remove


10. Front Bearing - Remove
1.
Drive out the front bearing (A) with a brass drift and a hammer.


NOTE: enu_12713377_2.0 Where icon is shown, click for further information.


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1828_3.0_enu_14740958_5.0

enu_12713377_2.0
Detailed information, notes, and precautions
enu_12714505_1.0
Torque: N·m (kgf·m, lbf·ft)
enu_12714524_1.0
Replace
*1
These parts have inspection items.

1. Front Bearing - Install
1.
Use a hand press to install a new front bearing (A) in the drive-end housing, with the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.

2. Front Bearing Retainer - Install


3. Rotor - Install


4. Bearing Holder - Install
NOTE: Align the protrusions (A) of the bearing holder with the grooves (B) of the stator assembly.


5. Stator Assembly - Install


6. Brush Holder - Install
1.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.
2.
Install the brush holder (A).
3.
Pull out the pin or drill bit.

7. Terminal Insulator - Install


8. End Cover - Install


9. Heat Shield - Install


Brush Holder

1. Brush - Inspect
1.
Measure the length of both brushes (A) with a vernier caliper (B). If either brush is shorter than the service limit, replace the brush holder.
Alternator Brush Length
Standard (New):
10.5 mm (0.413 in)
Service Limit:
1.5 mm (0.059 in)

Rotor

1. Rotor Slip Ring - Test
1.
Check for continuity between the slip rings (A):
If there is continuity, go to step 2.
If there is no continuity, replace the rotor assembly.
2.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
If there is continuity, replace the rotor assembly.