Starting System & Charging System (H6DO): Generator: Disassembly

Remove the four through-bolts.

Fig 1: Locating Four Through-Bolts
Courtesy of SUBARU OF AMERICA, INC.
Heat the portion (A) of rear cover to 50°C (122°F) with a heater drier.

Fig 2: Identifying Heated Portion Of Rear Cover
Courtesy of SUBARU OF AMERICA, INC.
Then insert the tip of a flat tip screwdriver into the gap between stator core and front cover. Pry them apart to disassemble.

Fig 3: Inserting Tip Of Flat Tip Screwdriver Into Gap Between Stator Core And Front Cover
Courtesy of SUBARU OF AMERICA, INC.
Hold the rotor with a vise and remove pulley nut.

Fig 4: Removing Pulley Nut
Courtesy of SUBARU OF AMERICA, INC.

CAUTION: When holding the rotor with a vise, place aluminum plates or wooden pieces on the vise jaws to prevent rotor from damage.

Fig 5: Identifying Front Cover, Pulley, Nut And Rotor
Courtesy of SUBARU OF AMERICA, INC.
Remove the ball bearing.
1. Remove the bolt, and then remove the bearing retainer.
  
  Fig 6: Identifying Bearing Retainer Bolt
  Courtesy of SUBARU OF AMERICA, INC.
2. Firmly install an appropriate tool (such as a fit socket wrench) to bearing inner race.
  
  Fig 7: Identifying Appropriate Tool On Bearing Inner Race
  Courtesy of SUBARU OF AMERICA, INC.
3. Push the ball bearing off the front cover using a press.
Remove the bearing from rotor using a bearing puller.

Fig 8: Removing Bearing From Rotor Using Bearing Puller
Courtesy of SUBARU OF AMERICA, INC.
Separate the connection between rectifier and stator coil to remove stator coil.
CAUTION: Do not allow a 180 - 270 W soldering iron to contact the terminals for more than 5 seconds at once because the rectifier cannot withstand so much heat.

Fig 9: Removing Stator Coil
Courtesy of SUBARU OF AMERICA, INC.
Remove the IC regulator.
1. Remove the screws which secure IC regulator to rear cover.
  
  Fig 10: Identifying Screws Securing IC Regulator To Rear Cover
  Courtesy of SUBARU OF AMERICA, INC.
2. Unsolder the connection between IC regulator and rectifier to remove IC regulator.
  
  Fig 11: Removing IC Regulator
  Courtesy of SUBARU OF AMERICA, INC.
Remove the brush.
1. Remove the cover A.
  
  Fig 12: Identifying Cover A
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover B.
  
  Fig 13: Identifying Cover B
  Courtesy of SUBARU OF AMERICA, INC.
3. Separate the brush from connection to remove.
  
  Fig 14: Removing Brush From Connection
  Courtesy of SUBARU OF AMERICA, INC.
Remove the rectifier.
1. Remove the bolts which secure rectifier.
  
  Fig 15: Locating Bolts Securing Rectifier
  Courtesy of SUBARU OF AMERICA, INC.
2. Remove the cover of terminal B.
  
  Fig 16: Locating Cover Of Terminal B
  Courtesy of SUBARU OF AMERICA, INC.
3. Remove the nut of terminal B, and then remove the rectifier.
  
  Fig 17: Locating Nut Of Terminal B
  Courtesy of SUBARU OF AMERICA, INC.