Alternator & Regulator: Overhaul: Disassembly

1. On diesel engine alternators, remove vacuum pump housing. Carefully remove rotor and vane assembly from shaft to prevent damage to vanes or "O" ring. Tape shaft splines to prevent damage to oil seal.
2. Remove 3 through bolts. Insert screwdriver between front housing and stator and pry downward to separate. On some models, stator and rear cover may be hard to remove as a ring is used to lock rear bearing.
   NOTE: Heat center of rear cover using a 200-watt soldering iron to facilitate rear stator and cover removal.
3. Place rotor in a soft-jawed vise with pulley side up. Remove nut, washer, pulley, fan (if used) and spacer(s). Remove rotor drive end housing and 2 seals. Remove rotor from vise. Press rotor out of front housing. Remove bearing retainer (if used) and front bearing.
4. Remove brush holder screws, rectifier screws, and nut from terminal "B+". Remove stator assembly from diode end housing. Detach slinger from brush holder (if used). Unsolder 3 stator leads from main diodes on rectifier.
5. When separating rectifier from brush holder, unsolder 2 plates soldered to rectifier. Remove condenser from "B+" terminal. Lift out rectifier assembly and brush holder. Remove vacuum pump oil seal (if used).

NOTE: Hold stator lead with needle nose pliers to prevent rectifier from overheating.

Fig 1: Exploded View of Mitsubishi Alternators