Charging System (Service Information): Generator: Disassembly: Disassembly

REMOVE GENERATOR REAR END COVER
1. Remove the 3 nuts and generator rear end cover.
  
  Fig 1: Identifying Clutch Pulley And Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil assembly.
  
  Fig 2: Identifying 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 assembly.
  
  Fig 3: Identifying Screws & Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 4: Identifying Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  
  Fig 5: 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
3. Remove the generator washer.
  
  Fig 6: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE CLUTCH PULLEY
1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
  
  Fig 7: Removing Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  NOTE:
  Do not reuse the generator pulley cap.
2. Mount the generator drive end frame in a vise tightly.
3. Confirm SST (A) and (B) shown in the illustration.
  
  Fig 8: Identifying SST (A) And (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63021
4. Place the rotor shaft end into SST (A).
  
  Fig 9: Placing Rotor Shaft Into SST (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 10: 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 11: Removing Clutch Pulley Using SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  NOTE:
  - Check that the drive end frame is secured in the vise tightly.
  - Hold SST (A) tightly during the operation.
7. Remove SST from the generator assembly.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator rotor assembly from the generator drive end frame.
  
  Fig 12: Identifying 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 generator drive end frame.
  
  Fig 13: Identifying Retainer Plate & Drive End Frame Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.
  
  Fig 14: Tapping Out Drive End Frame Bearing From Drive End Frame Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100