Rear Terminal Alternators: Reassembly
- Never use solvent to clean rotor, stator or bearings. Wipe parts off with suitable clean cloth. Install bearing in front housing, pressing on outer race only. Install bearing retainer.
- If stop ring was removed from rotor shaft, install new ring by sliding it over end of shaft and into groove. Do not open stop ring with snap ring pliers or stop ring will be permanently deformed. Install bearing spacer on rotor shaft with recessed side against stop ring.
- Install rotor in front housing and clamp housing in vise. Install fan spacer, fan, drive pulley, lock washer and nut on rotor shaft. Remove rotor and housing assembly from vise.
- Press bearing in rear housing, providing support close to bearing boss. Bearing should be flush with housing. Position brush wiring connector over brush terminal and install insulator. Install springs and brushes in holder. Use toothpick or stiff wire to hold brushes against spring tension.
- Install brush holder in rear housing and install attaching screws. Press holder firmly against housing while tightening. Be sure ground brush wiring connector is positioned under screw before tightening.
- Connect stator neutral lead to rectifiers. On flat type rectifiers with built-in diodes, position stator terminal insulator and stator neutral lead on rectifier assembly. Insert terminal screw and press into position. Neutral lead terminal should not move if screw is pressed to proper depth.
- On stacked type rectifiers with exposed diodes, place stator neutral lead and dished washer on rectifier assembly. Insert terminal screw and rotate it 1/4; turn to lock it in place.
- If ground screw was removed, install in same manner as other screws, depending on type of rectifier. Wrap stator winding leads around terminals of rectifier assembly and solder them, using 100 watt soldering iron and resin core electrical solder.NOTE: On 65 amp. alternators, push stator terminals onto rectifier assembly pins and position as shown in Fig 3. Solder in place.
- Install radio suppression capacitor and battery terminal insulator on rectifier assembly. Install insulator on stator terminal screw. Align terminal screws on rectifier assembly with holes in back of rear housing, and install stator rectifier assembly in rear housing.
NOTE: Be sure terminal insulators are seated in their recesses.
- Install insulators, washers and nuts on proper terminals. Insulators are color coded - black for "STA" terminal; red for "BAT" terminal and orange for "FLD" terminal.
- Wipe rear end bearing surfaces on rotor shaft with clean rag. Place rear housing and stator assembly over rotor and align scribe marks made during disassembly. Seat machined portion of stator core into stop in each end housing. Install through bolts.
- Remove toothpick or stiff wire from brush holder.