Generator Overhaul

Disassembly Procedure

TOOLS REQUIRED
^ J39200 Digital Multimeter
^ J28509-A Bearing Remover
^ J 26900-5 Vernier Caliper J 38276 Puller Adapter
^ J 35452 Generator Pulley Remover/Installer
^ J 35419 Bearing Installer
^ J22888 Universal Puller
^ J 29533-A/BT-8127 Oxygen Sensor Wrench

1. Remove the generator from the vehicle.
2. Refer to Charging System Description.
3. Scribe matchmarks (1) on the front and rear housings to ensure proper assembly.
4. Remove the nut (3) and the terminal insulator (2).




5. Remove the following from the end cover (1):
^ 1 bolt
^ 3 nuts (2)
^ The plate terminal
6. Remove the end cover.




7. Remove the brush holder cover.
8. Remove the 5 screws (2).

IMPORTANT: Note the correct orientation of the brush holder for easier installation.

9. Remove the brush holder (3).
10. Remove the voltage regulator (1).
11. Remove the seal.




12. Remove the 4 screws (2) and the rectifier holder (1).
13. Remove the 4 rubber insulators.




14. Remove the pulley nut using the J 35452 or the J39194-B and a 10 mm socket. Loosen the nut with the 7/8 in box end wrench while holding the rotor shaft with the 10 mm socket wrench.
15. Remove the pulley.




16. Remove the 4 nuts (2) and the clip (1) from the rectifier end frame.
17. Remove the rectifier end frame using the J28509-A.
18. Remove the washer from the rotor.
19. Remove the rotor from the drive end frame.




20. Inspect the front bearing (2) for rough operation, wear or damage. If necessary, replace the front bearing.
21. Remove the 4 screws (1).
22. Remove the bearing retainer.




23. Press out the front bearing using an appropriate adaptor.




24. Inspect the rear bearing (2) for rough operation, wear or damage. If necessary, replace the rear bearing.
25. Remove the rear bearing outer cover (1).





IMPORTANT: Do not damage the rotor fan during bearing removal.

26. Remove the rear bearing from the rotor using the J22888.
27. Remove the rear bearing inner cover.

Measuring Procedure




1. Measure the resistance between the rotor slip rings (2) with the J 39200. If the resistance is greater than specifications, replace the rotor.

Rotor Slip Ring Resistance 2.7-3.1 ohms at 20°C (68°F)




2. Measure the resistance between the rotor slip rings (2) and the rotor (1) with the J 39200. If the resistance is less than 5 ohms, replace the rotor.




3. Measure the rotor slip rings (2) with the J 269OO-5. If the diameter is less than the minimum, or if the slip rings are rough or scored, replace the rotor.

Standard Slip Ring Diameter
14.2-14.4 mm (.559-.567 in)

Minimum Slip Ring Diameter
12.8 mm (.504 in)




4. Measure the resistance between all stator leads (1) with the J 39200. If the resistance is greater than 5 ohms for any measurement, replace the stator.




5. Measure the resistance between all stator leads (1) and the stator core with the J39200. If the resistance is less than 5 ohms, replace the stator.




6. Measure the exposed brush length (2) with the J 26900-5. If the exposed length is less than the minimum, replace the brush holder assembly

Standard Exposed Brush Length
10.5 mm (0.413 in)

Minimum Exposed Brush Length
1.5 mm (0.059 in)




7. Measure the resistance between the rectifier positive terminal (4) and each rectifier terminal (3) with the J 39200. Reverse the probes and measure the resistance again. If the resistance is not less than 5 ohms in one measurement and greater than 5 ohms in the other measurement, replace the rectifier.




8. Measure the resistance between the rectifier negative terminal (3) and each rectifier terminal with the J 39200. Reverse the probes and measure the resistance again. If the resistance is not less than 5 ohms in one measurement and greater than 5 ohms in the other measurement, replace the rectifier.

Assembly Procedure




1. Install the rear bearing inner cover (3).




2. Install the rear bearing to the rotor shaft using the J35419 and a press.
3. Install the rear bearing outer cover.




4. Install the front bearing using a suitable adaptor and a press.




5. Install the bearing retainer.

NOTE: Refer to Fastener Notice in Cautions and Notices.

6. Install the four screws (1).

Tighten
Tighten the 4 screws to 3.0 N.m (27 lb in)




7. Install the rotor to the drive end frame.
8. Install the washer to the rotor.
9. Install the rectifier end frame by using a 29 mm socket or other suitable adaptor and a press.
10. Install the wire clip (1) and 4 nuts (2).

Tighten
^ Tighten the nut with the clip to 5.5 N.m (48 lb in).
^ Tighten the 3 nuts to 4.5 N.m (40 lb in).




11. Install the pulley and the nut using the J 35452 or the J 39194-B. Tighten the 718 in nut while holding the rotor shaft stationary with the 10 mm socket.

Tighten
Tighten the pulley nut to 111 N.m (81 lb ft).




12. Install the 4 rubber insulators.
13. Install the rectifier and the 4 screws (2).

Tighten
Tighten the 4 screws to 3 N.m (26 lb in).




14. Install the seal on the rectifier end frame.
15. Install the voltage regulator (1).

IMPORTANT: Note the correct orientation of the brush holder.

16. Install the brush holder (3).
17. Install the 5 screws (2).

Tighten
Tighten the 5 screws to 2.0 N.m (18 lb in).

18. Install the brush holder cover.




19. Install the end cover.
20. Install the plate terminal
21. Install the 3 nuts (2) and 1 bolt.

Tighten
^ Tighten the 3 nuts to 4.5 N.m (39 lb in)
^ Tighten the 1 bolt to 4 N.m (35 lb in)




22. Install the terminal insulator (2) and the nut (3).

Tighten
Tighten the nut to 4 N.m (36 lb in).

23. Inspect that the rotor turns smoothly.
24. Install the generator to the vehicle.