Alternator Brush: Service and Repair

DISASSEMBLY

1. Remove the generator (GEN) from the vehicle.
2. Remove the four housing bolts.







3. Use a flat-blade screwdriver to separate the generator front housing and stator and coil.
4. Remove the generator front housing and generator rotor from the stator and coil.
5. On this generator, remove the nut and insulator from the B-terminal on the generator rear housing.







6. Remove the rectifier screw and the two voltage regulator screws that secure the voltage regulator (VR) and rectifier to the generator rear housing and bearing.







7. Remove the stator and coil, with the voltage regulator and rectifier attached, from the generator rear housing and bearing.







8. Unsolder the stator and coil from the rectifier.

CAUTION: Work quickly, applying the soldering iron for no more than 5 seconds to avoid heating and possible damage to the diodes.







9. Unsolder the voltage regulator from the rectifier.







10. Remove the two shields from the voltage regulator.







11. Replace the generator brushes if they are worn at or near the wear limit line as shown.







12. If it is necessary to replace the generator brushes, remove the solder from the generator brush pigtails at the points shown. Remove the generator brushes.

CAUTION: When solder melts, it could damage the voltage regulator.

ASSEMBLY

1. Insert new generator brushes and solder the generator brush pigtails in place in the voltage regulator.

CAUTION: When solder melts, it could damage the voltage regulator.

2. Reassemble the rectifier, voltage regulator and stator and coil by soldering the leads in the reverse order of disassembly.

CAUTION: Work quickly, applying the soldering iron for no more than 5 seconds to avoid damage to the diodes.







3. Use only rosin core solder. Hold the stator and coil leads with a pair of needlenose pliers when soldering. The pliers act as a heat sink, and will protect the diodes. Do not solder for more than five seconds.
4. Position the stator and coil, with rectifier and voltage regulator attached, on the generator rear housing and bearing.







5. Install the stator and coil in the generator rear housing and bearing by evenly pressing the stator and coil into the generator rear housing and bearing.







6. Install the rectifier screw and the two voltage regulator screws.







7. Depress the generator brushes. Use a stiff wire (a straightened paper clip will work) to retain the generator brushes in the voltage regulator while assembling the generator.
8. On this generator, replace the nut and insulator on the B-terminal.
9. Heat the generator rear housing and bearing around the generator rear bearing seat with a 200 W soldering iron. Heat the generator rear housing and bearing to no more than 50-60°C (122-140°F).
10. Position the generator front housing and generator rotor to the stator and coil.
11. Install the four housing bolts. Tighten the housing bolts alternately and evenly to draw the halves together uniformly. Tighten the housing bolts to 3.0-6.3 N.m (27-56 lb-in).
12. Remove the wire (or paper clip) used to hold the generator brushes.
13. Rotate the generator pulley manually. There should be no drag and the generator rotor should turn easily 360 degrees. If the generator rotor does not spin easily, disassemble the generator to determine the cause.
14. Install the generator in the vehicle.