Charging System - Generators & Regulators: Overhaul: Generator: Assembly
To assemble, reverse disassembly procedure. Use generator Pulley Set Nut Wrench Set (SST 09820-63010) to install generator pulley. Place SST "C" securely into a vise. Install SST "A" and "B" and generator into SST "C". See Fig 1. On 2004 models, before installing brush holder, push brushes back into holder and install .039" (1 mm) pin into brush holder hole. See Fig 2. On 2003 models, after installing brush holder, install rubber insulators on lead wires with flat side toward housing. Install generator holder w/rectifier, while pushing it with 4 screws. Tighten pulley nut in the opposite direction of disassembly. See TORQUE SPECIFICATIONS . After completing assembly, verify rotor turns smoothly.