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Disassembly

 0001

- FIRST & MOST IMPORTANTLY!!  Disconnect battery Negative terminal.

- Place reference mark on the alternator with a marker, liquid paper, hacksaw blade mark; whatever works for you !

- Disconnect all wires and fan belt from alternator; remove alternator from car.

0002

- Remove nut, pulley, fan from alternator.

0003

- Remove 4 bolts that hold the housing together.

- Remove front cover

- Separate the housings - "a pry bar or big screwdriver may help."

- Remember where different spacers go.

0004

- The "rotor" can be removed now; "that is the part that spins". 

- The brushes will fly out; they are spring loaded. We'll fix them later! 

- The rotor "brush surface" can be cleaned with very light sand paper or emery cloth - make sure it is free of dirt.

0005

- Remove the 3 nuts from the inside that hold the stator.

0006

- Carefully remove the stator it's a little hard it may be rusted in the casing, again a pry bar or big screwdriver may help!

- Careful of the 3 wires that will come with the stator!

0007

- Remove the 3 screws that hold that hold the brush holder, voltage regulator, resistor, and some have a diode trio. The screws are insulated and need to go back in there original holes!

- Take all the parts out.

0008

- All parts removed from casing except for the rear bearing. 

- Note: the casing that houses the rear bearing is very fragile.  Be careful pressing it out (with a socket and a vise or tapping it with a hammer) - the housing can crack easily.

0009

- You can buy a re-build kit for $20 or so or you can be lazy and get a whole rebuilt alternator for $100 . This rebuild will only take 1 hour or so of your time and you know the job was done right.

0010

- Front bearing with 3 bolt cover removed and bearing repacked with grease.

0011

- Front bearing and 3 bolts removed from housing. 

- You can also replace the bearings , the front one comes in the kit.  The rear one which is the smaller one is about $10. 

- One is held in with 3 screws and the other is pressed in use a vise and a socket to press it out.

0012

- Brush assembly as removed from alternator.

0013

- Before reassembly insert brush holder stick to facilitate reassembly of alternator.

- I am using a WD40 tube in this case.


Reassembly
- You will be working with the rear casing.
- Install the voltage regulator  "no screws yet" !
- Rectifier bridge and condenser. - Brush holder. "Do not remove the small wire that is holding the brushes in it will go threw the casing".
- Install the diode trio.
- Install the 3 insulated screws and the resistor.
- Install the stator and the 3 nuts "make sure the wires are in the right place"
- Install rotor "slip rings toward the bottom, and spacer if there was one there"!
- Install front cover, realign you marks.
- Install 4 screws.
- Install the washer pulley and nut.
- Pull the small wire that was holding the brushes in through the rear casing.
- Spin the alternator by hand and it should be smooth with a little resistance.
- Re-install on vehicle hook up connections and negative battery terminal.
- Start vehicle and with multimeter  check voltage on battery with car running, you should get anything from 13.0 to 15.0 volts depending on the condition of the battery! 
- Make sure all connections are clean and tight!

Part Identification (Click on picture for larger image)

0014
 
1) Nut & Washer 9) Resistor
2) Pulley 10) Diode Trio
3) Fan 11) Brushes
4) Casing Bolts (4) 12) Regulator
5) Front Cover 13) Rectifier Bridge
6) Front (Big Bearing) 14) Capicitor
7) Stator 15) Rear Casing
8) Rotor  

Tips & Tricks

- When you take something apart, I lay the parts down left to right as I disassemble, then for re-assembly, go from right to left!
- Or take pics with digital cam.
- If you decide to replace the rear "small" bearing be careful when you push it out and back in, the rear casing is not that strong. I used two sockets to support it.
- If you are handy with a multimeter you can check the separate pieces for shorts, "opens" and other problems.
- I clean the casing in Varsol, dry them them and use re-builders gray to paint them with. AND FINALLY...
- If you want to make sure that your handiwork has been done correctly - you can take the rebuilt alternator to a store like Parts Source, Canadian Tire or Hosie and Brown and they can test it to make sure that it is charging properly.

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