Repair Procedures: Disassembly

Insert an aluminum plate and fix the alternator on the vise.
NOTE: Fixing the alternator housing may damage the stator coil. Therefore, tighten the fixing bolts on the front and rear housings instead.
Follow the order below and install the special tool (SST No.: 09373 - D2200) designed to remove and install the overrunning pulley.
Support and fix the overrunning pulley removal/installation tool on the worktable.
While holding with overrunning pulley removal/installation tool, use the ratchet to tighten the torque wrench counterclockwise .
Remove the bush (A).

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Remove the rear cover (A).
Tightening torque:

3.8 - 5.3 N.m (0.39 - 0.54 kgf.m, 2.8 - 3.9 lb - ft)

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Loosen the fixing bolts (A) and remove the brush holder assembly (B).

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Prepare a fixing pin (C) to be inserted to the hole (B) in order to fix the brush on the brush holder (A).

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Loosen the four through bolts (A).
Tightening torque:

4.9 - 6.9 N.m (0.5 - 0.7 kgf.m, 3.6 - 5.1 lb - ft)

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Hit the (A) area on the alternator front case with a rubber hammer to remove the front housing (B).

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Fix a tripod gear pulley (A) at the center of the rotor shaft and rear housing to remove the rotor (B) from the rear housing.

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NOTE: Place a soft cloth under the rotor to prevent the slip ring or fan from being damaged when you drop the rotor.
Fix the rotor on the cylindrical support to remove the rotor more easily.

NOTE: If you remove the rear housing, you can see a wave washer (A). Remove the wave washer while making sure that it does not touch the slip ring (B). (Be careful not to damage the slip ring or contaminate it with oil or foreign substance.)

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Reassembly is the reverse order of disassembly.