Charging Systems: Alternators: Overhaul: Disassembly

Remove brush screws, insulating washers, and brush assemblies from end shield.
CAUTION: Stator is laminated. Use care not to burr stator or end shield.
Remove through bolts and pry between stator and drive end with blade of screwdriver (using slot provided on 100 amp.). Carefully separate drive end shield, pulley and rotor assembly from stator and rectifier end shield assembly.
NOTE: If negative heat sink diode straps (all but 100 amp.) are on top of positive heat sink straps, loosen 4 hex-head screws on negative rectifier and heat sink assembly. Remove two outer screws and remove heat sink assembly.
On all but 100 amp. alternators, remove nut, washer and insulator from "BAT" output terminal on outside of rectifier end shield. Remove round plastic insulator. Turn end shield over and remove nut and washer assembly from end shield stud. Remove capacitor, insulated washer and heat sink assembly. Remove round plastic insulator from "BAT" terminal hole. Remove mica insulator from end shield stud. If negative heat sink diode straps were under positive heat sink diode straps, remove 4 hex-head screws and remove heat sink assembly.
On 100 amp. alternators, remove nut and insulator (from inside end shield) securing heat sink assembly to end shield stud. Remove capacitor and insulator. From outside of end shield, remove nut and insulator attaching positive heat sink assembly stud. Remove positive and negative heat sink assemblies, noting location of insulators. Remove terminal block from end shield.
On all models, pulley is an interference fit on rotor shaft. Use suitable puller (C-4467 for 100 amp.; C-4068 or C-4333 for all others).
On 100 amp. alternators, remove screws attaching bearing retainer to drive end shield. On other models, pry retainer from shield with screwdriver. To separate rotor from end shield, support shield and tap rotor shaft with plastic hammer.
Drive end bearing is an interference fit to rotor shaft. Use puller (C-4333 for 100 amp. or C-4068 or C-4333 for all others). Rectifier end shield bearing is a press fit. Use support under end shield when pressing bearing out (C-4330 for 100 amp. or C-3770A and C-3925 for all others).