Charging System - Generators & Regulators: Overhaul: Generator: Disassembly

Use generator Pulley Set Nut Wrench Set (SST 09820-63010) to remove generator pulley. To remove pulley, install SST "A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Figure. Place SST "C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. See Figure. To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST "A" and "B", remove pulley nut and pulley.
Remove rear end cover. Remove nut and terminal insulator. See Fig 1-Fig 3 . Remove brush holder. Remove 3 screws and voltage regulator. Remove 4 screws and diode (rectifier) holder.
Using Bearing Puller (SST 09950-40011) or equivalent, remove rectifier end frame. See Fig 4. Remove generator washer from rotor. Remove rotor from drive end frame.

Fig 1: Exploded View Of 100-amp Generator (2003)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 2: Exploded View Of 100-amp Generator (2004)

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Fig 3: Exploded View Of 130-amp Generator (2004)

Fig 4: Removing Rotor With Bearing Puller Set