Disassembly [06/2017 - ]: Procedure

1. Using a screwdriver, remove the generator pulley cap from the generator pulley with clutch.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   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. Remove the 3 bolts and generator rear end cover from the generator coil assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the generator terminal insulator from the generator coil assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 2 screws and generator brush holder assembly from the generator coil assembly.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

1. Remove the 4 bolts.

   Courtesy 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

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   *a	Turn
   *b	Hold

3. Remove the bearing cover packing.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   NOTE:

   If the bearing cover packing breaks, remove the broken pieces completely.

   HINT: 

   The bearing cover packing may be installed on the generator rotor assembly.

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.

   Courtesy 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.

   Courtesy 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.

1. Remove the generator rotor assembly from the generator drive end frame.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

See step  3

1. Remove the 4 screws and retainer plate from the generator drive end frame.

   Courtesy 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.

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

   • SST: 09950-60010 
     1. 09951-00250
   • SST: 09950-70010 
     1. 09951-07100