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Disassembly [11/2016 - ]: 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.
      GTY291443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE:

      Do not reuse the generator pulley cap.

  2. REMOVE GENERATOR REAR END COVER 
    1. Remove the 3 nuts and generator rear end cover from the generator coil assembly.
      GTY442329Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE GENERATOR TERMINAL INSULATOR 
    1. Remove the generator terminal insulator from the generator coil assembly.
      GTY146425Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE GENERATOR BRUSH HOLDER ASSEMBLY 
    1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.
      GTY129806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE GENERATOR COIL ASSEMBLY 
    1. Remove the 4 bolts.
      GTY442330Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the generator coil assembly from the generator rotor 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
      GTY728471Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    3. Remove the washer from the generator rotor assembly.
      GTY432971Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *1 Washer
  6. 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.
      GTY441544Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Rotor Shaft
      • SST: 09820-63021 
      NOTE:

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

    3. 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.
      GTY724195Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      *a Turn
      *b Hold
    4. Remove SST from the generator pulley with clutch.
    5. Remove the generator pulley with clutch from the rotor shaft.
  7. REMOVE GENERATOR ROTOR ASSEMBLY 
    1. Remove the generator rotor assembly from the generator drive end frame.
      GTY426597Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  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.
      GTY146427Courtesy 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.
      GTY133160Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      • SST: 09950-60010 
        1. 09951-00250
      • SST: 09950-70010 
        1. 09951-07100
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