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Disassembly [11/2021 - ]: Procedure

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  1. REMOVE GENERATOR PULLEY CAP 
    NOTE:
    • Do not reuse the generator pulley cap.
    • If the generator pulley cap is removed, replace the generator pulley cap and generator pulley with clutch with new ones as the correct grease amount cannot be confirmed.
    HINT: Although grease will be observed when the generator pulley cap is removed, this does not indicate a malfunction.
    1. GTY1066041Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.
  2. REMOVE GENERATOR PULLEY WITH CLUTCH 
    1. GTY1077226Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Pulley with Clutch - -
      *a Rotor Shaft *b Turn
      *c Hold - -
      1. Secure the generator drive end frame in a vise between aluminum plates.
        NOTE:

        Do not overtighten the vise.

      2. Install SST (A) to SST (B) as shown in the illustration.
        • SST: 09820-63021 
      3. Fit the rotor shaft end into SST (A).
      4. Fit SST (B) to the generator pulley with clutch.

        HINT: 

        Make sure that SST (A) and (B) are secured to the rotor shaft and generator pulley with clutch.

      5. Loosen the generator pulley with clutch by turning SST (B) as shown in the illustration.
        NOTE:
        • Check that the generator drive end frame is secured in the vise tightly.
        • Hold SST (A) tightly during the operation.
    2. GTY1066079Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Remove SST (A) and (B) from the generator pulley with clutch.
      2. Remove the generator pulley with clutch from the rotor shaft.
      3. Remove the generator drive end frame from the vise.
  3. REMOVE GENERATOR REAR END COVER 
    1. GTY1075670Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      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.
  4. REMOVE GENERATOR TERMINAL INSULATOR 
    1. GTY1066055Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. GTY1066056Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE GENERATOR COIL ASSEMBLY 
    1. GTY1076719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Hold *b Turn
      1. Remove the 4 bolts.
      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
  7. REMOVE WASHER 
    1. GTY1076610Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE GENERATOR ROTOR ASSEMBLY 
    NOTE:

    Do not drop the generator rotor assembly.
    1. GTY1066558Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Generator Rotor Assembly *2 Generator Drive End Frame
  9. INSPECT GENERATOR DRIVE END FRAME BEARING 
    See step  3
  10. REMOVE RETAINER PLATE 
    1. GTY1066559Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE GENERATOR DRIVE END FRAME BEARING 
    1. GTY1077544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      1. Using SST and a hammer, tap out the generator drive end frame bearing.
        • SST: 09950-60011 
          1. 09951-00250
        • SST: 09950-70010 
          1. 09951-07100
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