Charging Systems: Charging: Generator: Disassembly

REMOVE REAR END COVER
1. Remove the nut and terminal insulator.
  
  Fig 1: Removing Nut & Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the bolt, 3 nuts, plate terminal, end cover and brush holder cover.
  
  Fig 2: Removing Bolt, Nuts, Plate Terminal, End Cover & Brush Holder Cover
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR
1. Remove the 5 screws, brush holder and voltage regulator.
2. Remove the seal plate from the rectifier end frame.
  
  Fig 3: Removing Brush Holder & Voltage Regulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE RECTIFIER HOLDER
1. Remove the 4 screws and rectifier holder.
2. Remove the 4 rubber insulators.
  
  Fig 4: Removing Rectifier Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE PULLEY
1. Hold SST (A) with a torque wrench, and tighten SST (B) clockwise to the specified torque.
  1. SST 09820-6301 1
  2. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
  Fig 5: Tightening SST Clockwise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Check that SST (A) is secured to the rotor shaft.
3. Mount SST (C) in a vise.
  
  Fig 6: Mounting SST In Vise
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
4. Insert SST (B) into SST (C), and attach the pulley nut to SST (C).
5. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration.
  NOTE: To prevent damage to the rotor shaft, do not loosen the pulley nut more than one-half of a turn.
6. Remove the generator from SST (C).
7. Turn SST (B), and remove SST (A and B).
  
  Fig 7: Turning & Removing SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. Remove the pulley nut and pulley.
REMOVE RECTIFIER END FRAME
1. Remove the 4 nuts and wire clip.
  
  Fig 8: Removing Nuts & Wire Clip
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the rectifier end frame.
  1. SST 09950-40011 (09951-04020, 09952-04010, 09953-04030, 09954-04010, 09955-04041)
    
    Fig 9: Removing Rectifier End Frame Using SST
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Remove the generator washer.
REMOVE ROTOR FROM DRIVE END FRAME