For 1990-2009 cars

### Disassembly Procedure

1. Remove the generator. Refer to Generator Replacement .
2. Mark a match line that cannot easily be removed on the end frame to make assembly easier.
3. Pry off the plastic cover to expose the stator connections.

Notice: If the stator connections are welded in, use just enough heat to melt the lead. Avoid using to much heat as it can damage the diodes.

4. Remove the stator connections from the rectifier bridge terminals by cutting the wires.
5. Pry off the baffle.
6. Remove the rectifier/regulator/brush holder assembly screws.

Important: If the brush can be reused, reassemble the brush to the holder with the retaining pin, after cleaning the brush with a soft, clean cloth.

7. Remove the brush holder assembly and the regulator.
8. Test the rectifier bridge by connecting the ohmmeter terminals to the bridge and the heat sink.
9. Retest by connecting the ohmmeter terminals in reverse.
10. Replace the rectifier bridge, if each reading is the same.
11. Test the remaining 2 diodes after the above procedure.

Important: Some kinds of digital ohmmeters are not suited for the test of the bridge diode. In this case, consult the manufacturer regarding the test capacity.

12. Test the diodes by connecting the ohmmeter terminals to the bridge terminal and the base plate. If the reading is the same, the rectifier bridge should be replaced.
13. Remove the generator through-bolts.

Important: The fastening torque of this nut is 81 N·m (60 lb ft) and may not normally be unfastened using hand strength.

14. Move to the drive end of the generator and remove the drive end bearing nut.
15. Remove the pulley and the collars.
16. Test the rotor for an open circuit using the ohmmeter with the drive end frame assembled. The reading should be sufficiently high, or the rotor must be replaced.
17. Test the rotor for open and short circuits. The reading should be 1.7-2.3 ohms, or the rotor should be replaced.
18. Remove the drive end frame from the shaft.
19. For vehicles with an internal generator fan, remove the drive end frame and the fan.
20. Remove the rotor assembly.
21. Remove the stator.
22. Test the stator for an open circuit using the ohmmeter.
23. Remove the ring in the slip ring end frame.

### Assembly Procedure

1. Install the new ring in the slip ring end frame.
2. Install the stator.
3. Position the rotor assembly shaft with the drive end frame in the slip ring end assembly until the gap between the outer lace and the end frame casting is 1.9 mm (0.075 in).

Notice: Refer to Fastener Notice in the Preface section.

4. Install the generator through-bolts.

Tighten
Tighten the generator through-bolts to 10 N·m (89 lb in).

5. Position the fan, the collars, and the pulley on the rotor shaft and secure with the nut.

Tighten
Tighten the generator drive end bearing nut to 81 N·m (60 lb ft).

6. Install the generator. Refer to Generator Replacement .
7. Weld the brush holder terminal to the regulator terminal, if removed.
8. Fix the brush holder with the retainer pin, and weld the regulator/brush holder assembled terminal to the rectifier terminal.
9. Apply silicone grease between the bridge and the end frame for radiation purposes.
10. Fasten the screws holding the rectifier regulator/brush holder assembly to the end frame.
11. Punch the new baffle with the pin into the brush.

Notice: If the stator connections are welded in, use just enough heat to melt the lead. Avoid using to much heat as it can damage the diodes.

12. Weld the connectors of the rectifier bridge.