Overhaul

Disassembly

1. Remove the alternator cover (A) using a screw driver after loosening the nuts (B).




2. Remove the slip ring guide (A) and then loosen the mounting bolts and disconnect the brush holder assembly (B).




3. Remove the pulley (A) using the SST (09373-27000) (B).




4. Loosen the 4 through bolts (A).




5. Disconnect the rotor (A) and cover (B).




6. Reassembly is the reverse order of disassembly.

Reassembly

1. Reassemble in the reverse order of disassembly.

NOTE:
- When reassembling OAD pulley, replace with new OAD cap.

Inspection

[Rotor]
1. Check that there is continuity between the slip rings (C).




2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).
3. If the rotor fails either continuity check, replace the alternator.

[Stator]
1. Check that there is continuity between each pair of leads (A).




2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.