Toyota 4Runner: Disassembly

DISASSEMBLY

PROCEDURE

1. REMOVE GENERATOR PULLEY CAP

(a) Using a screwdriver, remove the generator pulley cap.

2. REMOVE GENERATOR WITH CLUTCH PULLEY

(a) Mount the generator in a vise between aluminum plates.

(b) Install SST (A) and SST (B) to the generator with clutch pulley as shown in the illustration. SST: 09820-63021 Text in Illustration *1 Rotor Shaft NOTICE: Securely attach SST to the generator with clutch pulley and generator rotor shaft.

(c) Use a wrench to hold SST (A) and turn SST (B) counterclockwise to loosen the generator with clutch pulley.

*a	Hold
	Turn

NOTICE:

Be careful as the generator with clutch pulley or generator rotor shaft may be damaged if the position of SST is not securely maintained while performing this operation.

(d) Remove SST from the generator.

(e) Remove the generator with clutch pulley from the rotor shaft.

3. REMOVE GENERATOR REAR END COVER

(a) Remove the nut and cord clip.

(b) Remove the 3 nuts and generator rear end cover.

4. REMOVE TERMINAL INSULATOR

(a) Remove the terminal insulator from the generator coil.

5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

(a) Remove the 2 screws and brush holder from the generator coil.

6. REMOVE GENERATOR COIL ASSEMBLY

(a) Remove the 4 bolts.

(b) Using SST, remove the generator coil assembly.

SST: 09950-40011

09951-04020

09952-04010

09953-04020

09954-04010

09955-04071

09957-04010

09958-04011

*a	Hold
	Turn

7. REMOVE GENERATOR ROTOR ASSEMBLY

(a) Remove the generator washer.

(b) Remove the generator rotor assembly.

8. INSPECT GENERATOR DRIVE END FRAME BEARING

(a) Check that the drive end frame bearing is not rough or worn. If necessary, replace the generator drive end frame bearing.

9. REMOVE GENERATOR DRIVE END FRAME BEARING

(a) Remove the 4 screws and retainer plate from the drive end frame.

(b) Using SST and a hammer, tap out the drive end frame bearing from the drive end frame. SST: 09950-60010 09951-00250 SST: 09950-70010 09951-07100