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Disassembly [12/2019 - 10/2022]: Procedure

  1. REMOVE GENERATOR PULLEY CAP 
    1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.
      GTY291443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:
      • Do not reuse the generator pulley cap.
      • If the generator pulley cap is removed, replace the generator pulley cap and generator pulley with clutch with new ones as the correct grease amount cannot be confirmed.

      HINT: 

      Although grease will be observed when the generator pulley cap is removed, this does not indicate a malfunction.

  2. REMOVE GENERATOR REAR END COVER 
    1. Remove the 3 nuts and generator rear end cover from the generator coil assembly.
      GTY442329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY146425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY129806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY442330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly from the generator rotor 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
      GTY728471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    3. Remove the washer from the generator rotor assembly.
      GTY877429Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Washer
  6. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame in a vise between aluminum plates.
      NOTE:

      Do not overtighten the vise.

    2. Install SST (A) to SST (B) as shown in the illustration.
      • SST: 09820-63021 
      GTY907708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Fit the rotor shaft end into SST (A).
      GTY902241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
    4. Fit SST (B) to the generator pulley with clutch.
      GTY896610Courtesy 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.
      GTY724195Courtesy 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.
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly from the generator drive end frame.
      GTY426597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. INSPECT GENERATOR DRIVE END FRAME BEARING 

    See step  3

  9. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY146427Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.
      GTY133160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60011 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
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