Generators & Regulators: Overhaul: Generator: Assembly

Assemble generator in reverse order of disassembly procedure.

1. Before assembling, press the brush down into the brush holder. Fix it in that position by passing a wire (A) .08" (1 mm) diameter length 1.6-2" (4-5 cm) wire through the hole. See Fig 1 .
2. Install ball bearing using following steps:
   1. Set the ball bearing on the front cover. Securely install to the bearing outer race an appropriate tool, such as a fit socket wrench.
   2. Press the ball bearing into the specified position using a press.
   3. Install the bearing retainer.
3. Install the bearing (rear side) into the rotor shaft with a press.
   CAUTION: Grease should not be applied to rear bearing. Completely remove the oil if found on bearing box.
4. Heat the bearing box in the rear cover to 122-140°F (50-60°C). Then, press the rear bearing into the rear cover.
5. After reassembly, turn the pulley by hand to check that the rotor turns smoothly.

Fig 1: Retaining Brushes In Brush Holder

Courtesy of SUBARU OF AMERICA, INC.