Generators & Regulators: Overhaul: Alternator: Disassembly

Use exploded view of alternator for overhaul. See Fig 1.

1. Test the alternator and regulator before you remove them. See CHARGING SYSTEM INDICATOR TEST  under TROUBLE SHOOTING.
2. Remove the alternator. See ALTERNATOR  under REMOVAL AND INSTALLATION.
3. Remove the 4 through bolts.
4. Heat the rear bearing seat with a 1,000 watt hair dryer for about 5 minutes (129-140°F (50-60°C). See Fig 2.
NOTE: Be careful not to damage the stator with the tip of the screwdriver.
5. Separate the rear housing from the drive-end housing by inserting a flat tip screwdriver into the openings and prying them apart. See Fig 3.
6. Separate the rear housing "A" and drive-end housing "B" with the stator "C" attached to the rear housing. See Fig 4.
7. If you are not replacing the front bearing and/or rear bearing, go to BRUSHES  under BENCH TESTING. Clamp the rotor in a soft-jawed vise, remove the pulley locknut. See Fig 5.
8. Remove the rotor using a puller. See Fig 6.
9. Inspect the rotor shaft for scoring, and inspect the bearing journal surface in the drive-end housing for seizure marks. If either the rotor or drive-end housing is damaged, replace the alternator. If both the rotor and the drive-end housing are OK, go to next step.
10. Remove the rear bearing using the puller. See Fig 7.
11. Use a hand press to install the new rear bearing. Apply pressure only on the inner race to avoid damaging the bearing. See Fig 8.
12. Remove the front bearing retainer plate. See Fig 9.
13. Support the drive-end housing in a vise, and drive out the front bearing with a brass drift and hammer.
14. With a hammer, driver and attachment install a new front bearing in the drive-end housing. See Fig 10.