Pinpoint Test I: Generator Clutch Component Test
- Normal Operation and Fault Conditions
The generator clutch allows the generator rotor to continue to rotate when the engine or FEAD system slows. The clutch should slip freely and smoothly in a clockwise direction. It should not rotate freely in the counterclockwise direction. A loose FEAD belt or a weak or binding tensioner can cause the pulley to overheat. REFER to: Generator - 3.0L Power Stroke Diesel .
The generator is belt-driven by the engine FEAD system. There are several sources of generator noise which include bearing noise, electrical fault noise, generator or belt pulley misalignment. A generator with certain types of diode or stator failures can also produce an audible noise.
Possible Sources
- FEAD belt
- Loose bolts/brackets
- Generator/pulleys
Visual Inspection and Pre-checks
- Inspect the FEAD belt.
- Inspect for loose bolts/brackets.
- Inspect the generator/pulley.
- I1 INSPECT THE GENERATOR CLUTCH
- Remove the generator. REFER to: Generator - 3.0L Power Stroke Diesel .
- Inspect the generator clutch for heat damage.
Is there evidence of heat damage?
Yes INSTALL a new generator clutch. REFER to: Generator - 3.0L Power Stroke Diesel . INSPECT the FEAD system. REFER to: Accessory Drive Belt . No GO to I2 - I2 CHECK THE GENERATOR CLUTCH FOR SMOOTH ROTATION
- Using a small screwdriver or similar tool, insert the tool through the rubber button on the center of the pulley cap and pry off the cap. Discard the cap. A new cap must be installed.
- Using a 17 mm hex tool bit (such as a Snap-on® SAM17E2 or equivalent) and socket wrench, insert the 17 mm hex tool bit into the end of the clutch shaft.
- While holding the clutch pulley firmly by hand, turn the clutch shaft clockwise. The clutch shaft should rotate smoothly and freely.
Does the clutch shaft rotation feel rough or seized?
Yes INSTALL a new generator clutch (If equipped). REFER to: Generator - 3.0L Power Stroke Diesel . No GO to I3 - I3 CHECK FOR REVERSE ROTATION RESISTANCE
- While holding the clutch pulley firmly by hand, turn the clutch shaft counterclockwise.
Is there some resistance (a spring feel)?
Yes GO to I4 No INSTALL a new generator clutch (If equipped). REFER to: Generator - 3.0L Power Stroke Diesel . - I4 CHECK FOR REVERSE ROTATION
- While holding the clutch pulley firmly by hand, turn the clutch shaft counterclockwise.
Does the clutch shaft rotate freely?
Yes INSTALL a new generator clutch (If equipped). REFER to: Generator - 3.0L Power Stroke Diesel . No INSTALL a new generator (If equipped). REFER to: Generator - 3.0L Power Stroke Diesel .