Side Terminal Alternators: Reassembly
- Do not clean rotor, stator or bearings in solvent, but use a clean cloth to wipe these parts. Press new front bearing into housing, if necessary to replace it. Apply pressure on bearing outer race only. Install bearing retaining screws.
- Place inner spacer on rotor shaft and insert shaft into front housing and bearing. Install fan spacer, fan, pulley, lock washer and nut on rotor shaft. Use suitable tool (T65P-10300-B) to tighten nut.
- If rear bearing requires replacing, press new bearing in from inside housing until it is flush with boss on outer surface. Place brush terminal on brush holder. Install springs and brushes in holder and secure with stiff wire or toothpick. Install brush holder in rear housing. Push brush holder toward rotor shaft opening and tighten attaching screws.
- Install capacitor in rear housing. Place 2 rectifier insulators on bosses inside housing. Place insulator on "BAT" (large) terminal and position rectifier in rear housing. Install outside insulator on "BAT" terminal and install nuts on "BAT" and "GND" terminals (fingertight only).
- Install 4 rectifier attaching screws loosely. Tighten "BAT" and "GND" terminal nuts outside of housing and then 4 rectifier attaching screws. Attach capacitor lead to rectifier.
- Press brush holder lead on rectifier pin and solder securely. Do not permit rectifier to overheat. Position stator in rear housing and align scribe marks made during disassembly. Press 3 stator leads on rectifier pins and solder securely.
- Install rotor and front housing to stator and rear housing, aligning scribe marks.NOTE: Tighten 2 opposing bolts and then the 2 remaining bolts.
- Spin fan and pulley to check for binding. Remove brush retaining wire or toothpick. Place daub of waterproof cement over hole to seal it.