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Disassembly [10/2017 - ]: Procedure

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  1. REMOVE GENERATOR PULLEY CAP 
    1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.
      GTY659301Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. Secure the generator drive end frame 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 
      GTY633165Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Generator Rotor Shaft
    3. Using a wrench to hold SST A, turn SST B counterclockwise to loosen the generator pulley with clutch.
      GTY664086Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold
      Turn
      NOTE:

      Be careful as the generator pulley with clutch or generator 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 generator rotor shaft.
  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 from the generator coil assembly.
      GTY659307Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the terminal insulator from the generator coil assembly.
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY659306Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY659305Courtesy 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
      GTY654886Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      Hold
    3. Remove the generator washer.
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly from the generator drive end frame.
  8. INSPECT GENERATOR DRIVE END FRAME BEARING 

    See step  4

  9. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. Remove the 4 screws and retainer plate from the generator drive end frame.
      GTY659526Courtesy 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.
      GTY679747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
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