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Disassembly [09/2014 - 10/2015]: Procedure

  1. REMOVE GENERATOR REAR END COVER 
    1. Remove the 3 nuts and generator rear end cover.
      GTY402061Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the terminal insulator from the generator coil.
      GTY402059Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and brush holder from the generator coil.
      GTY402060Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY416771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
        7. 09958-04011
      GTY407221Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *a Turn
      *b Hold
  5. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
      NOTE:

      Do not reuse the generator pulley cap.

    2. Mount the drive end frame in a vise tightly.
    3. Confirm SST (A) and (B) shown in the illustration.
      • SST: 09820-63021 
      GTY674467Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (A)
      *2 SST (B)
    4. Place the rotor shaft end into SST (A).
      GTY667650Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Rotor Shaft
      *2 SST (A)
    5. Fit SST (B) to the generator pulley with clutch.
      GTY614511Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 Generator Pulley with Clutch
      *2 SST (B)
      *3 SST (A)
    6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
      NOTE:
      • Check that the drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
      GTY621994Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      TEXT IN ILLUSTRATION

      *1 SST (B)
      *2 SST (A)
    7. Remove SST from the generator assembly.
    8. Remove the generator pulley with clutch from the rotor shaft.
  6. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator washer.
      GTY675332Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the generator rotor assembly.
      GTY625378Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. INSPECT GENERATOR ROTOR BEARING 
    1. Check that the generator rotor bearing is not rough or worn.
      GTY418680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator rotor bearing.

  8. REMOVE GENERATOR ROTOR BEARING 
    1. Remove the 4 screws and retainer plate from the drive end frame.
      GTY402062Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator rotor bearing from the drive end frame.
      • SST: 09950-60010 
        1. 09951-00470
      • SST: 09950-70010 
        1. 09951-07100
      GTY399560Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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