MOTORCRAFT (AUTOLITE) With Separate Regulator: Overhaul: Reassembly

Rotor, stator, and bearings must not be cleaned with solvent. Wipe these parts off with suitable clean cloth. Press front bearing in front housing bearing boss, putting pressure on bearing outer race only. Install bearing retainer. If stop-ring on rotor drive shaft is damaged, install new stop-ring. Push new ring on shaft and into groove.
NOTE: Do not open ring with snap ring pliers as permanent damage will result.
Position rotor stop on drive shaft with recessed side against stop-ring. Position front housing, fan spacer, fan, pulley, and lock washer on drive shaft and install retaining nut. Tighten retaining nut using suitable tool.

Fig 1: DISASSEMBLED ALTERNATOR (TYPICAL)
Courtesy of FORD MOTOR CO.
If rear housing bearing was removed, support housing on inner boss and press in new bearing flush with outer end surface. Place brush springs, brushes, brush terminal, and terminal insulator in brush holder and hold brushes in position by inserting small piece of stiff wire in brush holder. Position brush holder assembly in rear housing and install mounting screws. Position brush leads in holder.
Wrap three stator winding leads around rectifier terminals and solder using suitable 100 watt soldering iron and rosin-core solder. Position stator neutral lead eyelet on stator terminal screw and install screw in rectifier assembly.

Fig 2: BRUSH HOLDER ASSEMBLY
Courtesy of FORD MOTOR CO.
For rectifier with diodes exposed, insert special screws through wire lug, dished washers, and circuit board. Turn screw 14 turn counterclockwise to lock. For single circuit boards with built-in diodes, insert screws straight through wire lug, insulating washer and rectifier, into insulator.
NOTE: Dished washers are to be used only on circuit board with exposed diodes. If dished washers are used on single circuit board, short circuit will occur.

Fig 3: BRUSH LEAD POSITIONS
Courtesy of FORD MOTOR CO.
For rectifier with booster diode plate (61 amp. only), position stator wire terminal on stator terminal screw and position screw into rectifier. Position square insulator over screw and into square hole in rectifier. Rotate terminal screw until it locks in position, then press in screw finger tight. Position stator wire, then press terminal screw into rectifier and insulator.
Position capacitor on rectifier terminals. On circuit board with exposed terminals, install "STA" and "BAT" terminal insulators. On single circuit board, position square stator-terminal insulator in square hole in rectifier assembly. Position "BAT" terminal insulator on "BAT" terminal. Position stator and rectifier assembly in rear housing. Make certain all terminal insulators are seated properly in appropriate recesses. Position "STA" (black), "BAT" (red), and "FLD" (orange) insulators on terminal bolts and install retaining nuts.
Wipe rear end bearing of rotor shaft with clean, lint free cloth. Position rear housing and stator assembly over rotor and align scribe marks made during initial disassembly. Seat machined portion of stator core into step in both end housings. Install housing through bolts. Remove brush retracting wire, and put small amount of water-proof cement over hole to seal from moisture.

Fig 4: STATOR AND RECTIFIER ASSEMBLY, 61 AMP. ALTERNATOR
Courtesy of FORD MOTOR CO.

If front bearing is being replaced, press new bearing into bearing boss putting pressure on outer race only. Install bearing retainer and tighten retainer screws until tips of retainer touch housing. Position rectifier assembly to stator, wrap stator leads around rectifier terminals and solder connections using 200-watt soldering iron and rosin core solder.
If rear housing bearing was removed, press in new bearing from inside of housing until bearing is flush with outer end surface. Put pressure on bearing outer race only. Install "BAT"-"GRD" insulator. Position stator and rectifier assembly in rear end housing. Install "STA" (purple) and "BAT" (red) terminal insulators on terminal bolts and install nut and washer assemblies.

Fig 1: STATOR LEAD CONNECTIONS EXCEPT 61 AMP. ALTERNATOR)
Courtesy of FORD MOTOR CO.

Fig 2: DISASSEMBLED 70 AMP. ALTERNATOR, TYPICAL OF 65
Courtesy of FORD MOTOR CO.

NOTE: Make certain that shoulders of all insulators, both inside and outside of housing, are seated properly before tightening nuts.
Position front housing over rotor and install fan spacer, fan, pulley, flat washer and lock washer, and nut on rotor shaft. Wipe rear end bearing surface of rotor shaft with clean cloth. Position rotor with front housing into stator and rear housing assembly, and align scribe marks made during disassembly. Seat machined portion of stator core into step in both housings and install through bolts.
Hold brushes in position by inserting stiff wire into brush holder. Position brush holder and cover assembly to rear housing and install three mounting screws. Remove brush retracting wire and seal hole with small amount of water-proof cement.