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Rear Terminal Models: Reassembly

  1. Press bearing in front housing bearing boss. Apply pressure on bearing outer race only. Install bearing retainer and screws. Tighten to proper specification. See TORQUE SPECIFICATIONS  table.
  2. Install new rotor stop ring on rotor drive shaft (if removed). 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 with recessed side against stop ring. Position front housing, fan spacer, fan, pulley and lock washer on rotor shaft. Install retaining nut and tighten to specification. See TORQUE SPECIFICATIONS  table.
  4. If rear housing bearing was removed, support housing on inner boss. Press new bearing in housing until it is even with outer end surface. Place brush springs, brushes, brush terminal and terminal insulator in holder.
  5. Brushes may be held in position by inserting a small piece of stiff wire in brush holder. See Fig 1.
    Fig 1: Assembled View Rear Terminal Brush Holder
    G10040Courtesy of FORD MOTOR CO.
  6. Position brush holder assembly in rear housing and install mounting screws. Ground brush lead must be positioned under mounting screw. See Fig 2.
    Fig 2: Brush Lead Wire Routing
    G10041Courtesy of FORD MOTOR CO.
  7. Rectifier must be installed on stator. On external diode rectifiers, position stator lead and dished washer on rectifier. Install stator lead screw. Rotate screw 1/4 turn counterclockwise to lock in position.
  8. On internal diode rectifier, place stator terminal insulator and stator lead on rectifier. Install terminal screw and press in position. Terminal screw should be installed enough to hold phase lead in place.
  9. Ensure that all insulators are installed. Place stator lead on rectifier leads. Solder leads using rosin core solder. Use care not to apply direct heat to rectifier.
  10. Position capacitor on rectifier terminals. Install "STA" and "BAT" terminal insulators on rectifier. Install stator and rectifier assembly in rear housing. Ensure all terminal insulators are seated in recesses.
  11. Install "STA" (Black), "BAT" (Red), and "FLD" (Orange) insulators on terminal bolts. Install retaining nuts and tighten to specification. See TORQUE SPECIFICATIONS  table.
  12. Clean rear bearing surface of rotor shaft with clean cloth. Position rear housing and stator assembly over rotor. Align scribe marks made during disassembly.
  13. Position machined portion of stator core in step area of both end housings. Install housing through bolts. Tighten to specification. See TORQUE SPECIFICATIONS  table. Remove brush retaining wire.
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