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Disassembly [09/2015 - ]: Procedure

  1. REMOVE GENERATOR PULLEY 
    • SST: 09820-63011 
      • 09820-06010
      • 09820-06021
    GTY105241Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Install SST1-A to the pulley shaft.
    2. Install SST1-B to SST1-A.
    3. Hold SST1-B and turn SST1-A counterclockwise with the specified torque.

      Torque: 39.2 N*m (400 kgf*cm, 29 ft.*lbf) 

      NOTE:

      Make sure that SST is secured to the generator pulley shaft.

    4. Mount 2 faces of SST2 in a vise.
      GTY661745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. With SST1-A and B attached to the generator, insert the pulley lock nut into the hexagon portion of SST2.
    6. To loosen the pulley nut, rotate SST1-A in the generator's normal rotation direction.
      GTY100746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      With SST2 (pulley nut) fixed in place, the pulley lock nut will loosen due to the rotation of SST1-A in the normal direction.

    7. Remove the generator from SST2.
    8. Fix SST1-B in place, and rotate SST1-A to the right to loosen it. Then remove SST1-A and B from the generator.
      GTY662532Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    9. Remove the pulley lock nut and generator pulley.
  2. REMOVE GENERATOR REAR END COVER 
    GTY512161Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 3 nuts and generator rear end cover from the generator coil.
  3. REMOVE GENERATOR TERMINAL INSULATOR 
    GTY105243Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the generator terminal insulator from the generator coil.
  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    GTY100756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 2 screws and generator brush holder from the generator coil.
  5. REMOVE GENERATOR COIL ASSEMBLY 
    GTY512160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    1. Remove the 4 through bolts.
    2. Using SST, remove the generator coil.
      • SST: 09950-40011 
        • 09951-04020
        • 09952-04010
        • 09953-04020
        • 09954-04010
        • 09955-04071
        • 09957-04010
        • 09958-04011
      GTY105251Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator washer.
      GTY520725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the generator rotor assembly from the drive end frame.
      GTY512157Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE GENERATOR ROTOR BEARING 
    1. Remove the 4 screws, and remove the retainer from the drive end frame.
      GTY105248Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, remove the generator rotor bearing from the drive end frame.
      • SST: 09950-60010 
        • 09951-00270
      • SST: 09950-70010 
        • 09951-07100
      GTY105244Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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