Alternator Overhaul - Jeep 1979 CJ-5 Technical & Service Manual

1E-10 CHARGING SYSTEM
BRUSH
H O L D E R R E G U L A T O R
H E A T SINK
O H M M E T E R
7 0 1 6 2
Fig. 1E-11 Testing Rectifier Bridge
(2) Install alternator to mounting bracket with
washers and screws. Tighten screws finger-tight only.
(3) Install alternator drive belt.
(4) Tighten belt to specified tension. Refer to Alter-
nator Belt Adjustment for proper belt tensioning
procedures.
(5) Tighten screw at sliding slot bracket to 20 foot-
pounds (27 N®m) torque. Tighten remaining screws to 30
foot-pounds (41 N*m) torque.
(6) Install terminal plug and battery lead to
alternator.
(7) Connect battery negative cable.
ALTERNATOR OVERHAUL
Oisassembly
CAUTION: As rotor and drive end housing assembly is
separated from slip ring housing assembly, the brushes
will spring out onto the rotor shaft and come in contact
with lubricant Immediately clean brushes which con-
tact shaft to avoid contamination by lubricant, or they
will have to be replaced.
(1) Scribe marks on alternator case for assembly
reference.
(2) Remove four through-bolts that connect rear
housing to front housing (fig. 1E-12).
(3) Separate front housing and rotor assembly from
stator assembly by prying apart with screwdriver
placed between stator assembly and front housing.
NOTE: After disassembly, place a piece of tape over
the rear housing bearing to prevent entry of dirt and
other foreign material, and also place a piece of tape
over the rotor shaft on the slip ring end. Use pressure-
sensitive tape and not friction tape, which would leave a
gummy deposit on the shaft. If brushes are to be reused,
clean with a soft, dry cloth.
(4) Place rotor in vise and tighten vise only enough
to permit removal of shaft nut.
NOTE: Avoid excessive tightening of the rotor in the
vise to prevent rotor distortion.
(5) Alternate pulley nut removal method requires
use of Allen wrench to hold rotor from turning while
loosening nut with wrench (fig. 1E-13).
(6) Remove shaft nut, washer, pulley, fan, and
collar.
(7) Separate drive end housing from rotor shaft.
(8) Remove three stator lead attaching nuts and
washers and remove stator leads from rectifier bridge
terminals.
(9) Separate stator from rear housing.
(10) Remove diode trio lead clip attaching screw and
remove diode trio.
(11) Remove capacitor lead attaching screw.
(12) Disconnect capacitor lead from rectifier bridge.
(13) Remove rectifier bridge attaching screws and
battery terminal screw.
(14) Remove rectifier bridge.
(15) Remove two brush holder screws and one diode
trio lead strap attaching screw (fig. 1E-14).
(16) Remove brush holder and brushes. Carefully
note stack-up of parts for assembly.
(17) Remove voltage regulator.
(18) Remove front bearing retaining plate screws.
(19) Press front bearing from front housing with
suitable tube or collar.
NOTE: If the bearing is in satisfactory condition, it
may be reused.
(20) PreSfc out rear bearing using tube or collar that
fits inside rear housing. Press from inside of housing
toward outside.
NOTE: Replace the bearing in the rear housing if its
lubricant supply is exhausted. Do not attempt to lubri-
cate and reuse a dry bearing.