Alternator - BOSCH W/External Regulator: Overhaul: Disassembly

CAUTION: Use needle nose pliers as heat sink when unsoldering stator to rectifier leads.

With alternator removed, place alternator assembly mounting lug in a soft jawed vise.
Hold pulley with tool (mini oil filter tool or equivalent), loosen and remove pulley mounting nut and lock washer. Remove pulley, pulley-to-fan spacer and pulley fan. See Fig 1.

Fig 1: Exploded View of Chrysler Corp. (Bosch) Alternator Check alternator for proper output; if not to specifications, dis- assemble and retest.
Remove woodruff key from rotor shaft. Remove brush holder mounting screw and brush holder. Disconnect capacitor terminal. Remove capacitor mounting screw and capacitor. Remove ground stud nut and washer from housing. Remove alternator through bolts.
Pry between stator and drive end shield with a screwdriver. Carefully separate drive end shield pulley and rotor assembly away from stator and rectifier end shield assembly.
Press rotor out of drive end shield and remove spacer. Remove front bearing retainer screws. Press out drive end shield bearing. Remove front drive bearing from front drive end shield.
Remove battery stud nut, lock washer, flat washer and stud insulators. Remove three rectifier assembly mounting screws. Remove stator and rectifier assembly.
Unsolder stator to rectifier leads. Scribe alignment mark on stator coil frame and housing assembly. Remove stator from rectifier end shield assembly.
Remove inner battery stud insulator. Remove rear bearing oil and dust seal and check rotor bearing surface for scoring. Using a puller (C-4068 or C-4333), remove rear rotor bearing from rotor shaft.

NOTE: During cleaning and inspection, DO NOT immerse stator field coil assembly, rotor assembly or rectifier assembly in cleaning solvent. Immersing these assemblies will damage parts. Clean with moist cloth only and wipe dry.