Alternator Overhaul

Exploded View


Special Tools Required
Handle driver (  07749-0010000)

Driver attachment, 42 x 47 mm (  07746-0010300)

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

1.Test the alternator and regulator before you remove them.

2.Remove the alternator.

3.Remove the harness stay and the three flange nuts from the alternator.


4.Remove the end cover.


5.Remove the brush holder.


6.Remove the four bolts, then remove the rear housing assembly (A), and washer (B).


7.If the pulley and/or front bearing need replacing, clamp the rotor in a vise with wood block. Remove the pulley cap, then slowly loosen the pulley.

NOTE: Do not use an impact wrench.


8.If you are not replacing the front bearing, go to 13. Remove the rotor from the drive-end housing.


9.Inspect the rotor shaft for scoring and inspect the bearing journal surface in the drive-end housing for seizure marks.

  • If the rotor is damaged, replace the rotor assembly.
  • If the rotor is OK, go to 10.

10.Remove the front bearing retainer plate.


11.Drive out the bearing with a brass drift and hammer.


12.With a hammer and special tools, install a new front bearing in the drive-end housing.


Alternator Brush Inspection

13.Measure the length of both brushes (A) with vernier calipers (B).

  • If either brush is shorter than the service limit,replace the brush holder assembly.
  • If the brush length is OK, go to 14.

Alternator Brush Length
Standard (New): 10.5 mm (0.41 in.) 
Service Limit: 1.5 mm (0.06 in.) 


Rotor Slip Ring Test

14.Check for continuity between the slip rings (A).

  • If there is continuity, go to 15.
  • If there is no continuity, replace the rotor assembly.


15.Check for no continuity between each slip ring and the rotor (B) and the rotor shaft (C).

  • If there is no continuity, replace the rear housing assembly, and go to 16.
  • If there is continuity, replace the rotor assembly.

Alternator Reassembly

16.If you removed the pulley, put the rotor in the drive-end housing, then loosely install the alternator pulley.

NOTE: Remove any oil from the pulley threads and rotor shaft contact areas.

17.Clamp the rotor in a vise with wood block. Slowly tighten the pulley to 110 N·m (11.2 kgf·m, 81.0 lbf·ft).

NOTE: Do not use an impact wrench.


18.Install the new pulley cap.

19.Remove any grease or oil from the slip rings.

20.Put the rear housing assembly and drive-end housing/rotor assembly together, then tighten the four through bolts.

21.Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (0.06 in.) diameter) to hold them there.


22.Install the brush holder, then pull out the pin.


23.Install the end cover.

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

25.Install the alternator, and drive belt.