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Starting System & Charging System: Generator: Disassembly

  1. Remove the rear cover.
    G11253736Courtesy of SUBARU OF AMERICA, INC.
  2. Remove the bushing from the terminal B.
    G11253737Courtesy of SUBARU OF AMERICA, INC.
  3. Remove the brush assembly.
    G11253738Courtesy of SUBARU OF AMERICA, INC.
  4. Remove the through bolt.
    G11253739Courtesy of SUBARU OF AMERICA, INC.
  5. Insert a flat tip screwdriver or similar tool wrapped with protective tape into the gap between stator core and the front cover, and remove the stator coil assembly from the rotor assembly.
    CAUTION:
    • Be careful not to deform or damage the parts during operation.
    • Disassemble while lifting the entire stator coil assembly evenly.
    G11253740Courtesy of SUBARU OF AMERICA, INC.
  6. Remove the bearing cover from the stator coil assembly.
    CAUTION: Do not reuse the bearing cover.
    G11253741Courtesy of SUBARU OF AMERICA, INC.
  7. Using a vise, secure the rotor assembly.
    CAUTION:
    • Place aluminum plates or wooden pieces between the contacting surfaces of the vise and rotor to prevent rotor damage.
    • Be sure to hold it with the wider surface of the pole core.
    • Do not tighten the vise more than necessary.
    G11253742Courtesy of SUBARU OF AMERICA, INC.
  8. Using a thin flat tip screwdriver, break and remove the dust cover.
    G11253743Courtesy of SUBARU OF AMERICA, INC.
  9. Remove the pulley.
    G11253744Courtesy of SUBARU OF AMERICA, INC.
  10. Remove the front cover from the rotor assembly.
    NOTE: If it is stuck, use a press to remove.
    G11253745Courtesy of SUBARU OF AMERICA, INC.
  11. Remove the bearing retainer from the front cover.
    NOTE: The following procedures from here are not necessary to be performed if bearing replacement is not required.
    G11253746Courtesy of SUBARU OF AMERICA, INC.
  12. Use the press to remove the ball bearing from the front cover.
    CAUTION: Press the inner race of bearing using an attachment, etc. suitable for the press.
    G11253747Courtesy of SUBARU OF AMERICA, INC.