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Alternators (With Electronic Regulator): 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.
  1. Position rectifier end shield bearing on suitable base tool (C-4201) and place alternator end shield on top of bearing so it is properly aligned with top part of suitable bearing press tool and press into place until bearing bottoms. Insert drive end bearing in shield and install bearing retainer plate. Position bearing and drive end shield on rotor shaft, and while supporting base of rotor shaft, press bearing end shield into position on rotor shaft with an arbor press and suitable adapter (C-3858).
    NOTE: Make sure bearing is installed squarely.
  2. Install pulley on rotor shaft. Shaft of rotor must be supported so all pressing force is on pulley hub and rotor shaft and not on bearings. Press pulley on rotor shaft until pulley contacts inner race of drive and bearing.
    CAUTION: Do not exceed 6800 pounds pressure.
  3. Install output terminal stud and insulator through end shield. Install heat sink assembly over studs, guide rectifier straps over studs of terminal block and install capacitor. Slide negative rectifier and heat sink assembly in place, position straps and install screws.
  4. Position stator over rectifier end shield and install winding terminals on terminal block and press stator pins into each end shield. Rotate leads so they cannot contact rotor or sharp edge of negative heat sink. Position rotor and drive end shield over stator and rectifier end shield and install through bolts. Compress both ends manually and tighten through bolts evenly, 20-30 INCH lbs.
  5. Install field brushes in insulated holders. Position vertical and horizontal field brushes in proper location in rectifier end shield. Place insulating washer on each field brush terminal and install lockwashers. Be sure that brushes are not grounded. Rotate pulley slowly by hand to be sure rotor fan blades do not hit stator winding leads.
    Fig 1: CHRYSLER CORP. ALTERNATOR
    G09358939Courtesy of CHRYSLER GROUP, LLC
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