Alternator Overhaul: Reassembly

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

• 1. Front Bearing - Install

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  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.

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  2. Install the front bearing retainer.

• 2. Rotor - Install

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• 3. Bearing Holder and Stator Assembly - Install

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  NOTE:  Align the protrusions (A) of the bearing holder with the grooves (B) of the stator assembly.

• 4. Brush Holder Assembly - Install

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  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.

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  2. Install the brush holder assembly.

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  3. Pull out the pin or drill bit.

• 5. Terminal Insulator, End Cover, and Heat Shield - Install

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  1. Install the terminal insulator and the end cover.

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  2. Tighten the three bolts.

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  3. Install the Heat Shield.

• 6. OAD Pulley - Install