Alternator Overhaul: Reassembly

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

Front Bearing - Install

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1. Install a new front bearing in the drive-end housing with a hammer, the driver handle, 15 x 135L (A), and the attachment, 42 x 47 mm (B).

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2. Install the front bearing retainer.

Rear Bearing - Install

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1. Use a hand press to install a new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.

Rotor - Install

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1. Install the spacer (A) and the rotor (B).

Pulley - Install

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1. Clamp the rotor in a soft-jawed vise.

2. Install the pulley.

Rectifier - Install

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Voltage Regulator/Brush Holder Assembly - Install

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Stator - Install

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Drive-End Housing/Rotor Assembly - Install

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1. Remove any grease or oil from the slip rings.

2. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (1/16 in) diameter) to hold them in place.

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

Fig 1: Alternator Housing Through Bolt Tightening Sequence

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4. Put the rear housing assembly (A) and the drive-end housing/rotor assembly (B) together, tighten the four through bolts, and pull out the pin (C).

Terminal Insulator - Install

Fig 2: Terminal Insulator Bolt Torque Specifications
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Heat Shield and Bracket - Install

Fig 3: Heat Shield and Bracket Bolt Torque Specifications
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