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Alternator - Models W/Integral Regulator: Overhaul: Reassembly

  1. Install bearing into front housing. Press on outer race only. Position bearing retainer on front housing. Install attaching screws. Tighten screws to specification. See TORQUE SPECIFICATIONS  table.
  2. Install new stop ring (if removed). Stop ring must be positioned in the groove farthest from rotor pole piece. Use care not to deform rotor stop ring during installation.
    NOTE: Do not open ring with snap ring pliers, as permanent damage will result.
  3. Position rotor stop on rotor shaft. Recessed side must be against stop ring. Place rotor in soft-jawed vise. Install front housing, fan, spacer, drive pulley, washer and nut on rotor shaft.
  4. Tighten nut to specification. See TORQUE SPECIFICATIONS  table. Remove rotor and housing from vise. Check rotor for rotation freedom.
  5. Place rear housing in arbor press. Support rear housing close to bearing boss. Install bearing until it is even with outside surface of housing.
  6. Clean rectifier base plate with a clean cloth. Apply a 3/32" (2.0 mm) wide by 3/4" (20 mm) long strip of Heat Sink Compound (ESF-M99G138-A) lengthwise across rectifier base plate.
    CAUTION: Rectifier is cooled by conducting heat directly into rear housing. Failure to apply heat sink compound may cause rectifier overheating.
  7. Ensure rear housing rectifier mounting surface is clean. Install rectifier into recessed mounting area. Install rectifier retaining screws. Tighten screws to specification. See TORQUE SPECIFICATIONS  table.
  8. Install stator in rear housing and align scribe marks. Install the 3 stator terminals onto rectifier blade terminals. Solder securely using resin core solder if connections were originally soldered. Use care not to apply direct heat to rectifier.
  9. Clean rear bearing surface of rotor shaft with a clean cloth. Install rear housing and stator over rotor. Align scribe marks. Ensure that machined area of stator core seats in both end housings.
  10. Install through bolts. Tighten to specification. See TORQUE SPECIFICATIONS  table. Install springs and brushes in brush holder.
  11. Retain brushes in place by inserting a 1 3/8" (35 mm) piece of stiff insulated wire into brush holder pin hole. See Fig 1 . Install nuts and washers in retaining slots of brush holder.
    Fig 1: Retaining Brush Assemblies
    G15350Courtesy of FORD MOTOR CO.
  12. Position brush holder backward so that nuts and washers fall toward nut side of slots. This allows clearance for brush terminal installation. Install brush terminals behind washers into slots. Clean brush holder mounting area on regulator assembly.
  13. Position brush holder on regulator. Install regulator-to-brush holder attaching screws. Tighten screws to specification. See TORQUE SPECIFICATIONS  table.
  14. Loop brush leads toward brush end of holder. Install adhesive backed insulator on "A" terminal screw head. Clean regulator mounting surface of alternator housing using a clean cloth.
  15. Install regulator and brush holder on rear housing. Install regulator attaching screws. Tighten screws to specification. See TORQUE SPECIFICATIONS  table. Remove brush retaining wire.
    CAUTION: Ensure brush retaining wire is removed. Regulator will be damaged if wire is not removed.
  16. Place a small amount of waterproof sealer over brush pin hole. Do not use silicone sealer. Rotate pulley to check for freedom of movement.
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