- Position grease retainer on rotor shaft. Press retainer onto shaft using Retainer Installer Tool (C-3921). Grease retainer is properly positioned when inner bore of installer tool bottoms on rotor shaft.
- Place rectifier end shield bearing on end of Bearing Installer Tool (C-4201). Place end shield on top of bearing so that bearing is properly aligned with bearing bore.
- Place a support tool under the end shield. Press the bearing in until it bottoms in the rectifier end shield. Insert drive end bearing into end shield. Install bearing retainer plate to hold bearing in place.
NOTE:
A metal spacer is supplied with replacement rotors and ball bearings, but is not part of original alternator assembly.
- Place spacer on pulley end of rotor shaft. Position bearing and drive end shield on rotor shaft. While supporting rotor shaft, press bearing and end shield into position on rotor shaft. See Fig 1.
CAUTION:
Be sure that bearing is installed squarely. If it is not, bearing damage will occur. Press bearing onto rotor shaft until bearing contacts spacer on rotor shaft.
- Support rotor shaft so that pressing force will be on pulley hub and rotor shaft. Install pulley on rotor shaft. Press pulley onto rotor shaft until pulley contacts inner race of drive end bearing.
CAUTION:
DO NOT
exceed 6800 pounds of force to install pulley. DO NOT
hammer on pulley.
- Install mica insulator on heat sink mounting stud in end shield. Install round plastic insulator in battery stud hole in end shield with flat side of insulator facing up. Install positive heat sink assembly by placing battery terminal through round plastic insulator and capacitor end over heat sink mounting stud.
- Guide rectifier straps over studs on terminal block. Install capacitor terminal over heat sink stud. Install capacitor insulator. Be sure that insulator properly seats in capacitor terminal and heat sink hole.
- Install capacitor bracket end shield and tighten attaching screws to 30-40 INCH lbs. (3.4-4.5 N.m). Install positive heat sink lock washer and nut. Tighten nut to 20-30 INCH lbs. (2.3-3.4 N.m).
- Turn end shield over and install round plastic insulator over battery terminal (flat side up). Install washer and nut and tighten to 30-50 INCH lbs. (3.4-5.6 N.m). Install negative rectifier and heat sink assembly into end shield. Place diode straps on terminal block studs.
- Install screws through end shield and into negative heat sink. Position stator over rectifier end shield and install stator leads to terminal block. Press stator into end shield. Tighten winding terminal nuts. Route stator leads so that they do not contact rotor or sharp edge of negative heat sink.
- Position rotor and drive end shield assembly over stator and rectifier end shield assembly. Align through bolt holes. Compress stator and both end shields by hand and install through bolts. Tighten through bolts to 25-55 INCH lbs. (2.8-6.2 N.m).
- Install field brushes in insulated holders. Position vertical and horizontal field brushes in proper location in rectifier end shield. On 114 amp alternators, install long terminal on bottom and short terminal on top.
- Place an insulating washer, lock washer and attaching screw on each field brush. Slowly rotate pulley by hand to ensure that rotor fan blades do not contact stator winding leads.