4-76 673831-Rev A
ELECTRICAL
4
Alternator Disassembly and Assembly
Figure 4-64: Alternator Disassembly
If the alternator screws or nuts have rust or other
corrosion, spray hardware with a rust penetrating fluid.
1. Use an impact driver to remove the pulley nut (1).
Remove pulley (2).
2. Remove nut (3) and insulation bushing (4).
3. Remove three screws (5). Note the location and
remove clamp (6) under screw (5).
4. Lift the rear cover (7) off the alternator.
Note the location and lengths for the brush holder and
regulator screws.
5. Remove two screws (8) and brush holder assembly
(9).
6. Remove screws (10 and 11) and voltage regulator
(12).
7. Remove four screws (13) securing stator leads to
rectifier (14). Lift rectifier off alternator.
8. Remove two screws (15) and two nuts (16).
9. Press on pulley end of rotor (20) to separate the
alternator frame.
Use caution not to damage slip ring assembly on the
brush end of rotor shaft when pressing rotor out of end
frame. Only press on the metal part of rotor shaft.
10. Press rotor (20) out of end frame (17).
11. If rear bearing (18) stayed on the rotor shaft, use a
bearing puller to remove the bearing.
12. If rear bearing (18) stayed in the end frame (17),
press the bearing out of the end frame.
13. Remove bearing cover (19).
14. Remove four screws (21) and bearing retainer plate
(22).
15. Press front bearing (23) and collar (24) out of drive
end frame (25).
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