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. Carefully separate drive end shield, pulley and rotor assembly from stator and rectifier end shield assembly.
NOTE: If negative heat sink diode straps (all except 114 amp.) are on top of positive heat sink straps, loosen 4 hex-head screws on negative rectifier and heat sink assembly and remove heat sink.
On all but 114 amp. alternators, remove nut and washer 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 insulator, capacitor and heat sink assembly. Remove mica insulator from end shield stud and positive rectifier and round plastic insulator from "BAT" terminal hole. If negative heat sink diode straps were under positive heat sink diode straps, remove negative rectifier and heat sink assembly.
On 114 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 insulator. Remove terminal block from end shield.
On all models, pulley is an interference fit on rotor shaft. Use suitable puller (C-4467 for 114 amp.; C-4068 or C-4333 for all others) to remove.
On 114 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 114 amp. or C-4068 or C-4333 for all others) to remove. Rectifier end shield bearing is a press fit. Use support under shield when pressing bearing out with suitable tool (C-4330 for 114 amp., C-3770A and C-3925 for all others).