Heat Shield, End Cover, and Terminal Insulator - Remove
1.
Remove the Heat Shield.
2.
Remove the three bolts.
3.
Remove the end cover and the terminal insulator.
3.
Brush Holder Assembly - Remove
4.
Brush - Inspect
1.
Measure the length of both brushes (A) with a vernier caliper (B). If either brush is shorter than the service limit, replace the brush holder assembly.
Alternator Brush Length
Standard (New):
10.5 mm (0.413 in)
Service Limit:
1.5 mm (0.059 in)
5.
Stator Assembly and Bearing Holder - Remove
6.
Rotor - Remove
NOTE: 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.
7.
Rotor Slip Ring - Test
1.
Check for continuity between the slip rings (A):
If there is continuity, go to step 2.
If there is no continuity, replace the rotor assembly.
2.
Check for continuity between each slip ring and the rotor (B) and the rotor shaft (C).
If there is continuity, replace the rotor assembly.
8.
Front Bearing - Remove
1.
Remove the front bearing retainer.
2.
Drive out the front bearing with a brass drift and a hammer.
NOTE: Refer to the Exploded View if needed during this procedure.
1.
Front Bearing - Install
1.
Use a hand press to install a new front bearing (A) in the drive-end housing, with the driver handle, 15 x 135L, and the bearing driver attachment, 42 x 47 mm.
2.
Install the front bearing retainer.
2.
Rotor - Install
3.
Bearing Holder and Stator Assembly - Install
NOTE: Align the protrusions (A) of the bearing holder with the grooves (B) of the stator assembly.
4.
Brush Holder Assembly - Install
1.
Push the brushes (A) in, then insert a pin or drill bit (B) (about 1.6 mm (1/16 in) diameter) to hold them there.
2.
Install the brush holder assembly.
3.
Pull out the pin or drill bit.
5.
Terminal Insulator, End Cover, and Heat Shield - Install
