Cleaning and Inspection

CAUTION: WHEN REBUILDING AN INTEGRAL ALTERNATOR, USE ONLY HIGH TEMPERATURE BEARINGS. USE OF STANDARD PARTS WILL RESULT IN ALTERNATOR FAILURE.

1. Wipe the stator, rotor and front bearing with a clean cloth. Do not clean these parts with solvent.

2. Rotate the front bearing on the drive end of the rotor shaft. Check for any scraping noise, looseness or roughness. Look for excessive lubricant leakage. If any of these conditions exist, replace the bearing.

3. Inspect the rotor shaft rear bearing surface for roughness or severe chatter marks. Replace the rotor assembly if the shaft is not smooth.
4. Place the rear bearing on the slip ring end of the rotor shaft and rotate the bearing. Make the same check for noise, looseness and roughness as was made for the front bearing. Inspect the rollers and cage for damage. Replace the rear bearing if these conditions exist or if the lubricant is lost or contaminated.

5. Check the slip rings for nicks and scratches. These may be removed by turning down the slip rings. Do not go beyond a minimum diameter of 31 mm (1.22 inches). If the rings are badly damaged, replace the rotor assembly.

6. Check all wire leads on both the rotor and stator assemblies for loose or broken connections. Check the windings for burned insulation. Replace parts that show signs of burned insulation.
7. Check the pulley and fan for excessive looseness on the rotor shaft and for cracks or other damage. Replace any pulley or fan that is loose, cracked or bent out of shape.

8. Check both the front and rear housings for cracks, particularly in the webbed areas at the mounting ear. Replace a damaged or cracked housing.

9. Wipe the heat transfer grease from the rectifier assembly base and rectifier mounting area of the rear housing with a clean cloth.

10. Replace the brushes if they are worn shorter than 6.35 mm (1.4 inch).

11. Remove the sealing compound from the brush pin hole in the regulator.

Assembly

1. Install the bearing in the front housing. Press on the outer race only.

2. Position the bearing retainer on the front housing and install the attaching screws. Tighten the screws to 2.8-4.8 N-m (25-40 in.lbs.).

3. If the stop ring was removed from the rotor shaft, install a new ring by sliding it over the end of the shaft and into the groove. Do not open the ring with snap ring pliers as permanent deformation of the ring will result.

4. Install the rotor stop on the rotor shaft with the recessed side against the stop ring.

5. Install the rotor in the front housing and clamp the housing in a vise equipped with protective jaws.

Figure 11:

6. Install the fan spacer, fan, drive pulley, flat washer and nut on the rotor shaft. Tighten the nut to 82- 135 N-m (60-100 ft.lbs.) using tool T65P-10300-B or equivalent (Figure 11).
7. Remove the rotor and housing assembly from the vise and check for free rotation of the rotor in the housing.

8. Support the rear housing close to the bearing boss to prevent damage to the housing and install the bearing using a suitable arbor press. Press the bearing into the bore until it is flush with the outside rear surface of the housing.

9. Wipe the rectifier assembly base plate with a clean cloth. Apply a 2.0 mm (3/32 inch) wide by 20 mm (3/4 inch) long strip of ESF-M99G138-A heat sink compound lengthwise across the rectifier assembly base plate.
10. Wipe the rectifier mounting surface of the rear housing with a clean cloth and seat the rectifier into the recessed mounting area.

CAUTION: THE RECTIFIER ASSEMBLY IS COOLED BY CONDUCTION RECTIFIER HEAT DIRECTLY INTO THE HOUSING. FAILURE TO REMOVE FOREIGN MATERIAL FROM THE MOUNTING SURFACES OR FAILURE TO APPLY HEAT SINK COMPOUND MAY CAUSE RECTIFIER OVERHEATING.

11. Install the four rectifier assembly attaching screws. Tighten the screws to 2.8-4.0 N-m (25-35 in.lbs.).

12. Position the stator assembly in the rear housing and align the scribe marks made during disassembly. Push the three stator terminals onto the rectifier blade terminals and solder securely using resin core electrical solder. Work quickly to prevent overheating the rectifier.

13. Wipe the rear end bearing surface of the rotor shaft with a clean, lint-free cloth.

14. Position the rear housing and stator assembly over the rotor and align the scribe marks made during disassembly.

15. Seat the machined portion of the stator core into the stop in both end housings and install the housing through bolts. Tighten the bolts to 4.1-6.7 N-m (35-60 in.lbs.). Spin the rotor to check for free movement.

Figure 13:

16. Install the springs and brushes in the brush holder. Hold the brushes in place by inserting a 35 mm (1-3/8 inch) long piece of stiff wire into the brush holder pin hole. (Figure 13).

Figure 14:

17. Position the two nut and washer assemblies into the retaining slots in the brush holder. Tip the holder back slightly so that the nut and washer assemblies fall to the nut side of the slots. Insert the brush terminals past the washers and into the slots (Figure 14).

Figure 15:

18. Wipe the regulator base plate with a clean cloth. Position the regulator against the brush holder and install the regulator to brush holder attaching screws. Tighten the screws to 2.3-3.4 N-m (20-30 in.lbs.). Loop the brush leads toward the brush end of the brush holder (Figure 15).
19. Wipe the regulator mounting surface of the alternator rear housing with a clean cloth. Position the regulator and brush holder assembly onto the alternator rear housing.

20. Install the regulator attaching screws. Tighten the screws to 2.8-4.0 N-m (25-35 in.lbs.).
21. Remove the wire holding the brushes.

WARNING: THIS STEP IS IMPORTANT. FAILURE TO REMOVE THE WIRE WILL RESULT IN A SHORT CIRCUIT THAT MAY DESTROY THE REGULATOR.

22. Place a daub of waterproof sealer over the brush pin hole to prevent water entry.

NOTE: Do not use silicone sealer on brush pin hole.