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LUCAS Alternators: Overhaul: Disassembly

  1. Remove end cover and note wire positions and color. Remove screws attaching surge protection diode and brush assembly. Lift out brush assembly and surge protection diode. Regulator may be removed if desired.
  2. Unsolder stator wire connections and remove rectifier pack grounding strip. Withdraw rectifier pack. Remove through bolts.
    CAUTION: When necessary to solder or unsolder leads from diodes, use pliers as a heat sink by pinching diode pin with jaws of pliers. Solder connections quickly to prevent heat damage to diodes.
  3. Remove through bolts from alternator frame and carefully slip end bracket and stator off of rotor. (It may be necessary to tap lightly on an extractor or tube placed against outer bearing journal to separate rotor from end bracket.)
  4. Complete disassembly, if required, by removing pulley and drive key. Press rotor from drive end bracket and remove screws retaining end bearing in position. Replace as necessary.
    NOTE: Position of all washers, spacers and insulators must be noted for proper assembly.
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