Charging Systems: Alternators: Overhaul: Reassembly
- Place grease retainer on rotor shaft and press retainer onto shaft until suitable tool (C-3921) bottoms on shaft. Position rectifier end shield bearing on base of suitable tool (C-4201) and alternator end shield on top of bearing so it is properly aligned. With top part of tool placed on end shield, press into place until it bottoms.
- Insert drive end bearing in drive end shield and install bearing retainer plate to hold bearing in place. Position bearing and drive end shield on rotor shaft, and while supporting base of rotor shaft, press bearing end shield into position on rotor shaft with an arbor press and suitable adapter (C-3858).CAUTION: Make sure bearing is installed squarely.
- Install pulley on rotor shaft. Shaft of rotor must be supported so all pressing force is on pulley hub and rotor shaft and not on bearings. Do not hammer pulley on.
- Install mica insulator on stud in end shield, then install round plastic insulator flat face up in "BAT" stud hole in end shield. Install positive heat sink assembly and position straps. Install capacitor terminal over heat sink stud, then install capacitor insulator making sure it seats properly in terminal and heat sink hole. Secure capacitor bracket to end shield, then install and tighten heat sink nut and lock washer assembly. Turn end shield over and install plastic insulator, nut and washer assembly over "BAT" terminal.
- Slide negative rectifier and heat sink assembly into place, position straps and install screws. Position stator over rectifier end shield and install winding terminals on terminal block and press stator pins into each end shield. Install winding terminals nuts. Route leads so they cannot contact rotor or sharp edges of negative heat sink. Position rotor and drive end shield over stator and rectifier end shield and install through bolts. Compress both ends manually and tighten through bolts evenly to 25-55 INCH lbs.
- Install field brushes in insulated holders and position vertical and horizontal field brushes in proper location in rectifier end shield. Place an insulating washer on each field brush terminal before installing lock washers and screws. Be sure that brushes are not grounded. Rotate pulley slowly by hand to be sure rotor fan blades do not hit stator winding leads.