Disassembly Procedure
TOOLS REQUIREDJ22912-O1 Bearing Remover
1. Remove the generator from the vehicle.
2. Scribe matchmarks (3) on the front (4) and rear housing (2) to ensure proper assembly.
3. Remove 4 generator housing bolts from the front housing (2).
4. Using a flat-bladed tool, gently pry off the front housing (7) (with the drive pulley and rotor) from the stator coil (1) and rear housing (2).
NOTICE: To prevent damage to the rotor, place clean shop cloths between the rotor and the vise.
5. Place the front housing and rotor (3) into a vise, facing the drive pulley up.
6. Remove the drive pulley retaining nut.
7. Remove the drive pulley washer and drive pulley from the rotor.
8. Remove the front housing and rotor from the vise.
9. Remove the rotor and spacer from the front housing.
10. Remove the four screws (1, 3), the front bearing retainer and the front bearing from the front housing.
11. Remove the rear bearing (1) from the rotor (2) using a J22912-O1 and a press.
12. Remove the battery terminal retaining nut (2) from the rear housing.
13. Remove the stator leads from the rectifier using a soldering iron.
14. Remove four retaining screws (2) and the stator (3) from the rear housing.
15. Remove one nut and the rectifier from the rear housing.
16. Remove the regulator and the brush holder from the rear housing.
17. Remove the brush holder from the regulator.
18. Remove the brushes from the regulator.
18.1. Remove the brush lead wire cover (4)
18.2. Using a soldering iron, heat and disconnect the brush lead wires (2) from the regulator terminals (3).
18.3. Remove the brushes and the brush springs from the regulator (1).