Rebuild your own alternator

Ok, as some of you may know, I build alternators and starters for a living. I took a series of pictures of a Paseo alternator that came through my shop not long ago, figured I'd post the info here. Toyota alternators are same brand as honda uses.


http://mywebpages.comcast.net/DirtWeed/alternator/paseo-alternator.jpg

This is the back of the alternator before starting. Remove the battery post nut and insulator, then the 3 small nuts(some may have a small bracket with a small bolt also) holding the cover on.





http://mywebpages.comcast.net/DirtWeed/alternator/cover-removed-1.jpg


If you have access to an airgun you can remove the single nut holding the pulley on, then you will see this..

http://mywebpages.comcast.net/DirtWeed/alternator/bare-front-4.jpg

Remove the 4 nuts holding the housings together, a slight bump on the front of rotor and it should easily slide apart. Tap the rear housing slightly in a circular pattern and the rotor will slide out....

http://mywebpages.comcast.net/DirtWeed/alternator/split-open-5.jpg


This is what you should see now. There is a pair of screws retaining the brush holder in, a good #2 phillips will be needed for all the screws inside. After removing the brush holder it should look like this...





http://mywebpages.comcast.net/DirtWeed/alternator/brushholder-removed-2.jpg

Pay close attention to the condition of the copper rings, make sure they aren't grooved too deep, if they are it will take special tools to repair. The brushes I can send you preset in a brush holder if you so desire, parts with shipping inside USA should be less than $15, slightly higher to cross a border.

One screw holds the regulator to the rectifier(diode assembly), and 2 longer ones hold the regulator in place, then 4 very short screws will hold the wires to the rectifier. After removing these parts you should see this...


http://mywebpages.comcast.net/DirtWeed/alternator/bare-back-3.jpg


Remove the single nut from the front and the pulley should slide off like this....

http://mywebpages.comcast.net/DirtWeed/alternator/bare-front-4.jpg


Then remove the 4 nuts holding housings together, a slight bump on rotor and they should seperate. Then you should see this...

http://mywebpages.comcast.net/DirtWeed/alternator/split-open-5.jpg

Tap the rotor from the housing...


http://mywebpages.comcast.net/DirtWeed/alternator/rear-stripped-6.jpg

This is probably as far as most of you want to go. Removing and resetting the stator(ring of wire) is a risky thing, even for an experienced rebuilder. But if you are planning to powdercoat the housings...
Remove the 4 studs holding the stator in. bend the rectifier leads to the center, out of the way. Find a solid surface, then hit the mounting ears of the housing on a downward swing to knock the stator lose, working back and forth till it slides out... unless you have the special tools for pulling it.;) Then the 4 screws holding the bearing cover and bearing in.

http://mywebpages.comcast.net/DirtWeed/alternator/front-stripped-7.jpg

From here I get to use a few custom tools for cleaning..

http://mywebpages.comcast.net/DirtWeed/alternator/auto-parts-washer-8.jpg

http://mywebpages.comcast.net/DirtWeed/alternator/glass-blaster-9.jpg

And we have a steel shot blaster like this one from Viking

http://www.vikingcorporation.com/images/301.jpg


So the housings come out like this...

http://mywebpages.comcast.net/DirtWeed/alternator/steel-blasted-10.jpg


After cleaning, reinsulation, and replacing the bearings, we start re-assembly...

http://mywebpages.comcast.net/DirtWeed/alternator/going-back-11.jpg


Basically putting it back in reverse of tear-down, here's a few finished pics...

http://mywebpages.comcast.net/DirtWeed/alternator/done-12.jpg

http://mywebpages.comcast.net/DirtWeed/alternator/done-13.jpg

http://mywebpages.comcast.net/DirtWeed/alternator/done-14.jpg


Let me know if you need any parts, and look up your own alternators at



WAI (http://www.wai-wetherill.com/products/ymm.cfm)

sweet man, that is some really good info. The pics really help out for those wanting to do something like this. Only if everyone who gave directions were this involved....the world would be a better place.

Chocolate chips are great alternator cleaners

http://mywebpages.comcast.net/DirtWeed/alternator/auto-parts-washer-8.jpg

:)
Thanks for the info man, really cool of you to do.

Very welcome, thanks for the replies, as said, everybody should share a little how-to info...

mmmmm...alternator cleaners.......

fuckin great post!!!seriously

hershey kisses? I've never tried mixing candy and metal parts, but if chocolate cleans that well, sure.

The trick is getting the foil to stay on the chocolate....

Wait are those really hershey kisses???? I thought thats what they looked like but i just assumed they were something else and my stomach was screwing with my eyes????

if they are could you explain the chocolate thing? I'm confused hahaha.

Yeah man, go wash your car with some chocolate bars and come tell me how it turns out :lol:. I was kidding about them being kisses :)

is it me or were there some stuff repeating in his post

Yeah man, go wash your car with some chocolate bars and come tell me how it turns out :lol:. I was kidding about them being kisses :)

I figured that you were kidding. So what are those things? is it some kind of cleaner or something? Is it an aggregate to knock crap off the metal?

whatever it is I have access to One :lol: but don't know how to use it or even what it does!!!!! :screwy:

They are ceramic hunks of 'media' that basically scrub the parts dampened with solvent while tumbling in a locked cage. A 55 gallon drum cut in half, a 30 gallon drum with sections replaced by screen, a flywheel and an electric garage door opener can quickly be 'Monster Garaged' into a working cleaner. Instead of buying ceramic media, the collection of extra screw and nuts make a good scrubbing media.

ok thats what i thought it was at first, some kind of aggregate/ media for knocking stuff off the parts, then everyone started talking about chocolate.... I dunno guess my brain decided to take a nap without tellin me again...

'taco kisses for my ben!!!!!!'

nevermind southpark episode.