Charging Systems: Charging: Generator: Disassembly

REMOVE GENERATOR CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Identifying Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  SST 09820-63020
3. Clamp SST (A) in a vise.
  
  Fig 2: Setting Rotor Shaft To SST
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4. Place the rotor shaft end into SST (A).
  
  Fig 3: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 4: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown below.
  
  Fig 5: Identifying SST Turning Direction
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator assembly from the SST.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR REAR END COVER
1. Place the generator assembly on the clutch pulley.
  
  Fig 6: Identifying Generator Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and generator rear end cover.
  
  Fig 7: Identifying Generator Rear End Cover Nuts
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REMOVE GENERATOR TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 8: Identifying Terminal Insulator
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REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 9: Identifying Generator Brush Holder Assembly Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Identifying Generator Coil Assembly Bolts
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2. Using SST, remove the generator coil assembly.
  
  Fig 11: Using SST To Remove Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011)
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 12: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the generator rotor assembly.
  
  Fig 13: Identifying Generator Rotor Assembly
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REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate from the drive end frame.
  
  Fig 14: Identifying Bearing Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.
  SST 09950-60010 (09951-00250), 09950-70010 (09951-07100)
  
  Fig 15: Using SST & Hammer To Remove Generator Drive End Frame Bearing From Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002