Charging (Service Information): Generator: Disassembly: Disassembly

REMOVE CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Removing Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  
  Fig 2: Setting SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63020
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 3: Placing Rotor Shaft End Into SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 4: Fitting SST (B) To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 5: Loosening Pulley
  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: Placing Generator Assembly On Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and end cover.
  
  Fig 7: Identifying Clutch Pulley And Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 8: Locating Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 9: Locating Generator Brush Holder Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Identifying Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  
  Fig 11: Removing 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: Placing Generator Washer On Generator Rotor
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the rotor assembly from the drive end frame.
  
  Fig 13: Installing Rotor Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING See step 4
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate from the drive end frame.
  
  Fig 14: Removing Retainer Plate From Drive End Frame 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.
  
  Fig 15: Tapping Out Drive End Frame Bearing From Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100