Alternator & Regulator: Overhaul: Disassembly

1. Place a 200-watt soldering iron against rear bearing for 3-4 minutes to heat rear cover to 122-140°F (50-60°C). Carefully separate front case and rotor from rear cover and stator. See Fig 1 thru Fig 6 and Figure thru Figure .
2. Position rotor in vise. Remove pulley. Disassemble pulley, rotor and front case. Remove front bearing from front case. Using a bearing puller, remove rear bearing.
3. Remove "B" terminal nut and bushing from rear cover. Remove screws from brush holder and rectifier. Separate rear cover and stator. When unsoldering rectifier and stator leads, disconnect as quickly as possible (5 seconds maximum) to avoid damage to rectifier. To remove brushes from holder, unsolder pigtail from terminal.

Fig 1: Overhauling Alternator

Courtesy of MAZDA MOTORS CORP.

Fig 2: Overhauling Alternator

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Fig 3: Overhauling Alternator

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Fig 4: Overhauling Alternator

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Fig 5: Overhauling Alternator

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Fig 6: Overhauling Alternator

Courtesy of MAZDA MOTORS CORP.