Alternator Overhaul: Disassembly

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

• 1. OAD Pulley - Remove
• 2. Heat Shield, End Cover, and Terminal Insulator - Remove

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  1. Remove the Heat Shield.

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  2. Remove the three bolts.

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  3. Remove the end cover and the terminal insulator.

• 3. Brush Holder Assembly - Remove

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• 4. Brush - Inspect

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  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

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• 6. Rotor - Remove

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  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

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  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

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  1. Remove the front bearing retainer.

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  2. Drive out the front bearing with a brass drift and a hammer.