Disassembly and Reassembly

Alternator Components:

DISASSEMBLY




1. Remove the three through bolts.
2. Insert a flat screwdriver between the front bracket and stator core, and pry downward.

CAUTION
1. Do not insert the screwdriver too deeply, as there is a danger of damaging the stator coil.





2. The rear cover may be hard to remove because a ring is used to lock the outer race of the rear bearing. To facilitate removal of the rear cover heat the bearing box section with a 200-watt soldering iron.

Do not use a heat gun, as it may damage the diode assembly.





3. Secure the rotor in a vise with the pulley side up.

CAUTION: Be careful that the vise jaws do not damage the rotor.

4. Remove the pulley nut, then remove the spring washer, then the pulley, and then the spacer.
5. Remove the front bracket and two seals.
6. Remove the rotor from the vise.
7. Remove the brush holder screws, rectifier screws, and nut from the B terminal.
8. Remove the stator assembly from the rear bracket.
9. Detach the slinger from the brush holder.
10. When the stator is to be removed, unsolder the three stator leads to the main diodes on the rectifier.

CAUTION
1. When soldering or unsoldering, be careful not to heat the diodes for too long.
2. Be careful that excessive force is not exerted on the leads of the diodes.




11. When separating the rectifier from the brush holder, unsolder the two plates that are soldered to the rectifier

REASSEMBLY





Perform reassembly as the reverse procedure of disassembly. Pay attention to the following:

Before the rotor is attached to the rear bracket, insert a wire through the small hole in the rear bracket to lock the brush. After the rotor has been installed, the wire can be removed.