Overhaul

Alternator Overhaul





View

1. Alternator Exploded View

Exploded View





Disassembly

NOTE: Refer to the Exploded View if needed during this procedure.

1. Alternator End Cover





1. Remove the end cover (A).

2. Alternator Brush Holder





1. Remove the brush holder assembly.

3. Alternator Brush - Inspection

1. Measure the length of both brushes (A) with a vernier caliper (B).

If either brush is shorter than the service limit, replace the brush holder assembly.











4. Alternator Rear Housing Assembly





1. Remove the rear housing assembly.

5. Alternator Pulley





1. If the front bearing needs replacing, remove the pulley locknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench.

6. Alternator Rotor





1. Remove the drive-end housing.

7. Alternator Rotor Slip Ring - Test





1. Measure the resistance between the slip rings (A).

If the resistance is not within the standard, replace the rotor assembly.







2. Check for continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C).

If there is continuity, replace the rotor assembly.

8. Front Alternator Bearing





1. Remove the front bearing retainer.





2. Remove the front bearing.

Reassembly

NOTE: Refer to the Exploded View if needed during this procedure.

1. Front Alternator Bearing





1. Install a new front bearing in the driver-end housing with a hammer, the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.





2. Install the front bearing retainer.

2. Alternator Rotor





1. Install the drive-end housing.

3. Alternator Pulley





1. Install the pulley on the rotor and install the locknut, then torque the locknut to 110 Nm (11.2 kgfm, 81 lbfft).

4. Alternator Rear Housing Assembly





1. Install the rear housing assembly.

5. Alternator Brush Holder





1. Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them in place.





2. Install the brush holder, and pull out the pin.

6. Alternator End Cover





1. Install the end cover (A).

7. Alternator After Install - Check

1. After assembling the alternator, turn the pulley by hand to make sure the rotor turns smoothly and without noise.