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

PROCEDURE


  1. REMOVE GENERATOR PULLEY CAP

    A01VFLHE01
    Text in Illustration
    *1 Generator Pulley Cap

    1. Using a screwdriver, remove the generator pulley cap.

  2. REMOVE GENERATOR CLUTCH PULLEY

    A01VE5ME02
    Text in Illustration
    *1 Rotor Shaft

    1. Clamp the generator housing stay in a vise tightly.

    2. Place the rotor shaft end into SST(A).

      SST
      09820-63021
    3. A01VEQPE07
      Text in Illustration
      *1 Generator Clutch Pulley

      Fit SST(B) onto the generator clutch pulley.

    4. A01VFFNE04
      Text in Illustration
      *a Hold
      *b Turn

      Loosen the generator clutch pulley by turning SST(B) in the direction as shown in the illustration.

      Note


      • Check that the generator housing stay is secured in a vise tightly.

      • Hold SST(A) tightly during the operation.

    5. Remove SST from the generator assembly.

    6. Remove the clutch pulley from the rotor shaft.

    7. Remove the generator assembly from a vise.

  3. REMOVE GENERATOR TERMINAL INSULATOR


    1. A01VKRC

      Remove the nut and generator terminal insulator.

  4. REMOVE GENERATOR REAR END COVER


    1. A01VHXX

      Place the generator assembly on the generator clutch pulley.

    2. A01VGGEE01
      Text in Illustration
      *1 Rectifier Plate

      Remove the nut A, screw and rectifier plate.

    3. Remove the 2 nuts B and the generator rear end cover.

  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY


    1. A01VKI9E05
      Text in Illustration
      *1 Generator Brush Cover
      *2 Generator Brush Holder Assembly
      *3 Generator Plate Seal

      Remove the generator brush cover from the generator brush holder assembly.

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

    3. Remove the generator plate seal.

  6. REMOVE GENERATOR REGULATOR ASSEMBLY

    A01VK59

    1. Remove the 2 screws and generator regulator assembly.

  7. REMOVE GENERATOR HOLDER WITH RECTIFIER

    A01VILM

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

  8. REMOVE GENERATOR ROTOR ASSEMBLY

    A01VF02E01

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

      Text in Illustration
      *1 Terminal Insulator

    2. Remove the 4 nuts.

    3. A01VEI5E01
      Text in Illustration
      *1 Wooden Block
      *a Hold
      *b Turn

      Using SST, remove the generator rectifier end frame.

      SST
      09286-46011
    4. A01VKRQ

      Remove the generator washer from the generator rotor assembly.

    5. A01VFTAE05
      Text in Illustration
      *1 Wooden Block
      *2 Plastic Hammer

      Using a plastic hammer, remove the generator rotor assembly from the generator drive end frame assembly.

      Note

      Do not drop the generator rotor assembly.

      Tech Tips

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