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Disassembly [06/2015 - ]: Procedure

  1. REMOVE GENERATOR PULLEY CAP 
    1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.
      GTY484131Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
    2. Install SST (A) to SST (B) as shown in the illustration.
      • SST: 09820-63021 
      GTY485885Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the rotor shaft end into SST (A).
      GTY485658Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
    4. Fit SST (B) to the generator pulley with clutch.
      GTY487903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Pulley with Clutch
    5. Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.
      GTY493748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
      NOTE:
      • Check that the generator drive end frame is secured in the vise tightly.
      • Hold SST (A) tightly during the operation.
    6. Remove SST (A) and (B) from the generator pulley with clutch.
    7. Remove the generator pulley with clutch from the rotor shaft.
    8. Remove the generator drive end frame from the vise.
  3. REMOVE GENERATOR REAR END COVER 
    1. Place the generator assembly on the generator pulley with clutch.
    2. Remove the 3 bolts and generator rear end cover from the generator coil assembly.
      GTY489189Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY489199Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY434200Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY434201Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
        7. 09958-04011
      GTY485670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      *b Turn
    3. Remove the bearing cover packing.
      GTY442966Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      If the bearing cover packing breaks, remove the broken pieces completely.

      HINT: 

      The bearing cover packing may be installed on the generator rotor assembly.

  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly from the generator drive end frame.
      NOTE:

      Do not drop the generator rotor assembly.

      GTY290241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT GENERATOR DRIVE END FRAME BEARING 

    See step  4

  9. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY161294Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator drive end frame bearing.
      • SST: 09950-60010 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
      GTY490319Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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