Special Tools Required
Handle driver ( 07749-0010000)
Driver attachment, 52 x 55 mm ( 07746-0010400)
NOTE: Refer to the Exploded View as needed during this procedure.
|3.||Remove the four through bolts.|
|4.||Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F).|
|5.||Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart.|
NOTE: Be careful not to damage the stator with the tip of the screwdriver.
|6.||Separate the rear housing (A) and drive-end housing (B) with the stator (C) attached to the rear housing.|
|7.||If you are not replacing the front bearing and/or rear bearing, go to 15. Clamp the rotor in a soft-jawed vise, then remove the pulley locknut.|
|8.||Remove the rotor using a puller as shown.|
|9.||Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks.|
- If either the rotor or drive-end housing is damaged, replace the alternator.
- If both the rotor and the drive-end housing are OK, go to 10.
|10.||Remove the rear bearing using the puller as shown.|
|11.||Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing.|
|12.||Remove the front bearing retainer plate.|
|13.||Support the drive-end housing in a vise, and drive out the front bearing with a brass drift and hammer.|
|14.||With a hammer and the special tools, install a new front bearing in the drive-end housing.|
Alternator Brush Inspection
|15.||Measure the length of both brushes with a vernier caliper.|
- If either brush is shorter than the service limit, replace the rear housing assembly.
- If brush length is OK, go to 16.
Alternator Brush Length:
|Standard (New): ||19.0 mm (0.75 in.) |
|Service Limit: ||5.0 mm (0.2 in.) |
Rotor Slip Ring Test
|16.||Check that there is continuity between the slip rings (A).|
- If there is continuity, go to 17.
- If there is no continuity, replace the rotor assembly.
|17.||Check that there is no continuity between each slip ring (A) and the rotor (B) and the rotor shaft (C).|
- If there is no continuity, replace the rear housing assembly, go to 18.
- If there is continuity, replace the rotor assembly.
|18.||If you removed the pulley, put the rotor in the drive-end housing, then tighten its locknut to 111 N·m (11.3 kgf·m, 81.7 lbf·ft).|
|19.||Remove any grease or any oil from the slip rings.|
|20.||Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.8 mm (0.77 in.) diameter) to hold them there.|
|21.||Heat the rear bearing seat with a 1,000 W hair drier for about 5 minutes (50-60°C, 129-140°F).|
|22.||Put the rear housing assembly (A) and drive-end housing/rotor assembly (B) together, tighten the four through bolts (C) and pull out the pin (D).|
|23.||After assembling the alternator, turn the pulley by hand to make sure the rotor rotates smoothly and without noise.|