Alternator Overhaul: Disassembly

NOTE:  Refer to the Exploded View if needed during this procedure.

1. Heat Shield and Bracket - Remove

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2. Terminal Insulator - Remove

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3. Rear Housing/Stator Assembly and Drive-End Housing/Rotor Assembly - Separate

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   1. Remove the four through bolts.

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   2. Heat the rear bearing seat with a heat gun for about 5 minutes (122-140 deg.F (50-60 deg.C)).

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   3. Separate the rear housing from the drive-end housing by inserting a flat-tip screwdriver into the openings and prying them apart. NOTE:  Be careful not to damage the stator with the tip of the screwdriver.

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   4. Separate the rear housing/the stator assembly (A) and the drive-end housing/the rotor assembly (B).

4. Stator - Remove

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5. Stator - Inspect

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   1. Check for continuity between each lead (A). If there is no continuity, replace the stator. 2. Check for continuity between each lead and the coil core (B). If there is continuity, replace the stator.

6. Voltage Regulator/Brush Holder Assembly - Remove

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7. Brush - Inspect

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   1. Measure the length of both brushes with a vernier caliper. If either brush is shorter than the service limit, replace the brushes, go to step 2. Alternator Brush Length

   Standard (New):	23 mm (0.91 in)
   Service Limit:	5 mm (0.20 in)

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   2. Unsolder the brush leads from the voltage regulator/brush holder assembly with a 100 W soldering iron (A), then replace the brushes.

8. Rectifier - Remove

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9. Rectifier - Inspect

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   1. Check for continuity in each direction, between the B terminal and P terminals, and between the E terminal and P terminals of each diode pair. All diodes should have continuity in only one direction. Because the rectifier diodes are designed to allow current to pass in one direction, and the rectifier is made up of six diodes (six pairs), you must test each diode in both directions for continuity with an ohmmeter that has diode checking capability: a total of 24 checks. If any diode fails, replace the rectifier assembly. (Diodes are not available separately.)

10. Pulley - Remove

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    1. Clamp the rotor in a soft-jawed vise. 2. Remove the pulley nut, then remove the pulley.

11. Rotor - Remove

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    1. Remove the rotor using a puller as shown. 2. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks. NOTE:  If either the rotor or drive-end housing is damaged, replace the alternator.

12. Rotor Slip Ring - Test

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    1. Check for continuity between the slip rings (A): If there is continuity, go to step 2. If there is no continuity, replace the rotor assembly. 2. Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C): If there is no continuity, replace the rear housing assembly. If there is continuity, replace the rotor assembly.

13. Rear Bearing - Remove

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    1. Remove the rear bearing using the puller as shown.

14. Front Bearing - Remove

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    1. Remove the front bearing retainer.

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    2. Drive out the front bearing with a brass drift and a hammer.