GENERATOR(for TMC Made except Cold Area Specification Vehicles) DISASSEMBLY

PROCEDURE


  1. REMOVE WIRE HARNESS CLAMP BRACKET


    1. A01VK4U

      Remove the 2 bolts and remove the 2 wire harness clamp brackets.

  2. REMOVE GENERATOR PULLEY

    A01VFE1E03
    SST
    09820-63011   ( 09820-06010, 09820-06021 )

    Tech Tips

    SST 1-A and B 09820 - 06010
    SST 2 09820 - 06021
    Text in Illustration
    *a Turn
    *b Hold

    1. Clamp the generator housing stay in a vise.

    2. Hold SST 1-A with a torque wrench, and tighten SST 1-B clockwise to the specified torque.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

      Note

      Check that SST is securely fitted onto the generator rotor shaft.

    3. A01VLCTE04

      Insert SST 2, and attach the pulley nut to SST 2.

    4. A01VJG3E03
      Text in Illustration
      *a Hold
      *b Turn

      To loosen the generator pulley nut, turn SST 1-A in the direction shown in the illustration.

      Note

      To prevent damage to the rotor shaft, do not loosen the generator pulley nut by more than one half turn.

    5. Remove SST 2 from the generator.

    6. A01VF8SE06
      Text in Illustration
      *a Turn
      *b Hold

      Turn SST 1-B, and remove SST 1-A and B.

    7. Remove the generator pulley nut and generator pulley.

  3. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. Remove the nut and terminal insulator.

    2. Remove the nut, screw and rectifier plate.

    3. Remove the 2 nuts and rear end cover.

    4. A01VKI9

      Remove the brush cover from the generator brush holder assembly.

    5. Remove the 3 screws and generator brush holder assembly.

    6. Remove the plate seal.

  4. REMOVE GENERATOR REGULATOR ASSEMBLY

    A01VK2F

    1. Remove the 2 screws and generator regulator assembly.

  5. REMOVE GENERATOR HOLDER WITH RECTIFIER

    A01VJKT

    1. Remove the 3 screws and generator holder with rectifier.

  6. REMOVE GENERATOR ROTOR ASSEMBLY

    A01VFMM

    1. Remove the 3 terminal insulators from the rectifier end frame.

    2. Remove the 4 nuts.

    3. A01VHYYE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST, remove the rectifier end frame.

      SST
      09286-46011

    4. Remove the plate retainer.

    5. Remove the generator rotor assembly from the drive end frame.

      Note

      Do not drop the generator rotor assembly.

      Tech Tips

      If the generator rotor is engaged too firmly, gently tap the generator rotor shaft to remove it using a plastic hammer.