Charging Systems: Alternators: Overhaul: Reassembly
NOTE:
Insure correct rectifier is installed. Identifying part numbers are stamped on rectifier case and rectifiers are color coded; red for positive and black for negative.
- Support heat sink or rectifier end shield on adapter, then carefully apply pressure with screw until installer tool, rectifier and shield or heat sink are aligned. With rectifier started squarely in casting, slowly apply pressure with tool screw until rectifier collar bottoms against casting.NOTE: Installer support adapter should fit squarely around inner boss of rectifier and pressure must be applied to outer rim of rectifier. Do not use hammer to start rectifier in its bore. Rough handling will damage silicon wafer within rectifier.
- If stator leads were disconnected, clean leads and bend rectifier wire loop snugly around stator lead and solder with resin core solder.NOTE: Hold rectifier lead wire with pliers just below joint while soldering. Pliers will absorb heat from soldering and will protect rectifier. After soldering, push stator leads into slots cast in end shield and cement in position with MoPart cement, Part No. 2299314, or equivalent (to prevent interference with rotor fan). Test each replacement rectifier to insure it was not damaged by soldering or pressing operations.
- Support end shield on suitable tool (C-3925) with notch in support tool clearing raised section of heat sink. Press bearing into position using suitable tool (SP-3381).NOTE: New bearings are pre-lubricated and additional lubrication is not required. Insert drive end bearing in shield and install bearing retainer plate. Position bearing and shield on rotor shaft and, while supporting rotor shaft base, press bearing and shield into position.
- Install pulley on rotor shaft, supporting rotor so all pressing force is on pulley hub and rotor shaft, then press into position with an arbor press.CAUTION: Do not use force greater than 6, 800 lbs.
- Position stator on rectifier end shield, then position rotor end shield assembly on stator and rectifier end shield. Align through bolt holes in stator, rectifier end shield and drive end shield, then compress stator and both end shields by hand and install through bolts, washers and nuts. Install insulated brush in rectifier end and place bronze terminal on plastic holder with tab of terminal in recess in plastic holder. Place nylon washer on bronze terminal and install lockwasher, attaching screws, ground brush and screw. Rotate pulley slowly by hand to insure rotor fans do not hit rectifiers, capacitor lead, and stator connections.