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Side Terminal Models: Reassembly

  1. Press bearing into front housing. Apply pressure on bearing outer race only. Install bearing retaining screws. Tighten to specification. See TORQUE SPECIFICATIONS  table.
  2. Install spacer on rotor shaft. Place rotor in front housing. Install fan, spacer, pulley, lock washer, and nut onto rotor shaft. Tighten pulley nut to specification. See TORQUE SPECIFICATIONS  table.
  3. Install rear bearing in housing. Install bearing until bearing is even with boss outer surface. Install brush terminal, brushes and springs on brush holder.
  4. Insert a small piece of stiff wire in brush holder to retain brushes. See Figure. Install brush holder to rear housing and install attaching screws. Ensure that small wire extends through rear housing so wire can be removed.
  5. Push brush holder toward rotor shaft opening and tighten screws. Crack between brush holder and brush cavity in rear housing must be sealed using Sealer (D6AZ-19560-A).
    CAUTION: DO NOT use silicone base sealer for sealing brush cavity.
  6. Install capacitor to rear housing. Install rectifier insulators on bosses on inside of rear housing. Install insulator on "BAT" terminal of rectifier. Position rectifier in rear housing. Install outside insulator on "BAT" terminal.
  7. Install nuts on "BAT" and "GRD" terminals finger tight only. Install rectifier retaining screws. DO NOT tighten at this time. Tighten "BAT" and "GRD" terminals nuts to specification. See TORQUE SPECIFICATIONS  table.
  8. Tighten rectifier screws to specification. Secure capacitor lead to rectifier. Press brush holder lead on rectifier pin and solder leads.
  9. Install stator in rear housing aligning scribe marks. Press 3 stator leads onto rectifier pins. Solder leads using care not to apply direct heat to rectifier.
  10. Position rotor and front housing into stator and rear housing. Align scribe marks. Install through bolts and tighten. Rotate alternator to ensure free movement.
  11. Remove brush retaining wire. Apply small amount of waterproof cement over hole to seal from moisture.
CAUTION: DO NOT use silicone base sealer for sealing hole.
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