Generators & Regulators: Overhaul: Disassembly

1. Remove nut, lock washer, and pulley. Note position of spacer(s), then remove fan assembly and key. Scribe mark front and rear housings. Remove voltage regulator and remove screws holding alternator together. Separate front and rear housings.
2. Disconnect capacitor from terminal. Remove nut, insulator(s), screws, washers, and remove stator assembly. See Figure and Fig 1 . Unsolder stator from diode assembly. Remove bearing wave washer or "O" ring from rear housing.
3. Support front housing and carefully press out rotor. Do not allow rotor to fall. Remove screws securing bearing retainer. Remove retainer, front bearing and seal. Remove rear bearing from slip ring end of rotor.

Fig 1: 90 Ampere Alternator Other Bosch 90 amp alternators are similar.