Side Terminal Models: Reassembly
- Rotor, stator, and bearings must not be cleaned with solvent. Wipe these parts off with a clean, lint-free cloth. Press front bearing into front housing, putting pressure on bearing outer race only. Install bearing retaining screws. Install inner spacer on rotor shaft and install shaft into front housing and bearing.
- Install fan spacer, fan, pulley, lock washer, and nut onto rotor shaft. Tighten pulley nut. If rear bearing was removed, press new bearing in until it is flush with boss outer surface. Position brush terminal, springs, and brushes in brush holder and hold in position by inserting a small piece of stiff wire in brush holder.
- Install brush holder to rear housing and install attaching screws. Push brush holder toward rotor shaft opening and tighten screws. Install capacitor to rear housing and install attaching screw. Install two rectifier insulators on bosses inside rear housing. Install insulator on "BAT" terminal of rectifier, then position rectifier in rear housing.
- Install outside insulator on "BAT" terminal, then install nuts on "BAT" and "GRD" terminals finger tight. Install four rectifier attaching screws but do not tighten. Tighten terminal nuts on "BAT" and "GRD" terminals, then tighten four rectifier screws. Secure capacitor lead to rectifier. Press brush holder lead on rectifier pin and solder, using a 100 watt soldering iron.
- Install stator in rear housing and align scribe marks. Press three stator leads onto rectifier pins and solder, using a 100 watt soldering iron. Position rotor and front housing into stator and rear housing while aligning scribe marks. Install four through bolts and tighten. Spin fan and pulley to ensure nothing is binding inside alternator. Remove brush retracting wire, and put small amount of water-proof cement over hole to seal from moisture.