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Alternators - BOSCH: Overhaul: Disassembly

  1. Scribe mark for alignment on front and rear alternator housing. Remove nut, pulley, fan and key. Unscrew brush plate assembly and remove from alternator. Remove frame bolts and separate rear frame from front frame with rotor.
  2. Press rotor from frame and bearing from rotor. Remove insulation from wires and cut wires as close to soldered joints as possible. Diodes may be tested at this point without further disassembly.
    NOTE: On 400 & 600 series alternators, lift and secure brushes prior to disassembly.
  3. Use care with insulating bushings under positive diode carrier. To remove negative carrier, extract threaded studs. When one diode has been damaged due to short circuiting, the 3 complementing diodes must also be replaced. Loosen nuts on both "B+" terminal bolts and lift positive carrier (heat sink) up and back.
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