Charging System - Generators & Regulators: Overhaul: Generator: Disassembly

Use generator Pulley Set Nut Wrench Set (SST 09820-63011) to remove generator pulley. To remove pulley, install SST "A" and "B" to rotor shaft and tighten SST "B" clockwise to 29 ft. lbs. (39 N.m). See Fig 1. Place SST "C" securely into a vise. Verify that SST "A" is secured to rotor shaft and install SST "A" and "B" and generator into SST "C". Turn SST "A" in correct direction to loosen pulley nut. See Fig 1. To prevent damage to rotor shaft, DO NOT loosen pulley nut more than 1/2 turn. Remove generator from SST "C". Turn SST "A" and "B", remove pulley nut and pulley.
Remove nut and terminal insulator. Remove 3 nuts, plate terminal, end cover and brush holder cover. See Fig 2. Remove 2 screws and brush holder. Remove 3 screws and voltage regulator. Remove 4 screws and diode (rectifier) holder. Remove 4 rubber insulators.
Using Bearing Puller (SST 0928646011), remove rectifier end frame. Remove generator washer from rotor. Remove rotor from drive end frame.

Fig 1: Removing Generator Pulley

Fig 2: Exploded View Of Generator (2.0L)