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Disassembly [10/2014 - ]: Procedure

  1. REMOVE GENERATOR PULLEY CAP 
    1. Using a screwdriver, puncture the center of the generator pulley cap and pry it off.
      GTY519576Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Mount the generator assembly in a vise between aluminum plates.
    2. Install SST A and B to the generator pulley with clutch as shown in the illustration.
      • SST: 09820-63021 
      GTY513463Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
      NOTE:

      Securely attach SST to the generator pulley with clutch and rotor shaft.

    3. Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator pulley with clutch.
      GTY502092Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:

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

    4. Remove SST from the generator assembly.
    5. Remove the generator pulley with clutch from the rotor shaft.
    6. Remove the generator assembly from a vise.
  3. REMOVE GENERATOR REAR END COVER 
    1. Place the generator assembly on the generator pulley with clutch.
    2. Remove the 3 nuts and generator rear end cover.
      GTY506959Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY506960Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY506957Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY519575Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly.
      • SST: 09950-40011 
        1. 09951-04020
        2. 09952-04010
        3. 09953-04020
        4. 09954-04010
        5. 09955-04071
        6. 09957-04010
        7. 09958-04011
      GTY505264Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the washer.
      GTY506940Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the generator rotor assembly.
  8. INSPECT GENERATOR DRIVE END FRAME BEARING 
    1. Check that the bearing is not rough or worn and that it rotates smoothly.
      GTY515664Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      If necessary, replace the generator drive end frame bearing.

  9. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY506934Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a hammer, tap out the generator drive end frame bearing from the generator drive end frame.
      • SST: 09950-60010 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
      GTY512973Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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