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Disassembly [10/2015 - ]: Procedure

  1. REMOVE GENERATOR PULLEY CAP 
    1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.
      GTY661244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Mount the generator assembly in the vise between aluminum plates.
    2. Install SST A and B to the generator pulley with clutch as shown in the illustration.
      • SST: 09820-63021 
      GTY634573Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Rotor Shaft
      NOTE:

      Securely attach SST to the generator pulley with clutch and generator rotor shaft.

    3. Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator pulley with clutch.
      GTY645644Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:

      Be careful as the generator pulley with clutch or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

    4. Remove SST from the generator assembly.
    5. Remove the generator pulley with clutch from the generator rotor shaft.
    6. Remove the generator assembly from the vise.
  3. REMOVE GENERATOR REAR END COVER 
    1. Place the generator assembly on the generator pulley with clutch.
    2. Remove the 3 nuts and generator rear end cover from the generator coil assembly.
      GTY661269Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY683259Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY661265Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY661334Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
      GTY505264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator washer.
      GTY661256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the generator rotor assembly.
  8. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the generator drive end frame bearing is not rough or worn and that it rotates smoothly.
      GTY661255Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY683256Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.
      GTY683739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
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