Disassembly [12/2013 - 11/2016]: Procedure

WARNING: This page is about a different car, the 2016 Toyota Highlander, 2015 Toyota Highlander, and 2014 Toyota Highlander. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE GENERATOR PULLEY CAP

Using a screwdriver, remove the generator pulley cap.

GTY291443

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

NOTE:

Do not reuse the generator pulley cap.

REMOVE GENERATOR REAR END COVER

Remove the 3 nuts and generator rear end cover.

GTY442329

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR TERMINAL INSULATOR

Remove the generator terminal insulator from the generator coil assembly.

GTY146425

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR BRUSH HOLDER ASSEMBLY

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

GTY129806

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

REMOVE GENERATOR COIL ASSEMBLY

Remove the 4 bolts.

GTY442330

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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

GTY447715

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

Remove the washer.

GTY432971

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*1

Washer

REMOVE GENERATOR PULLEY WITH CLUTCH

Secure the generator drive end frame in a vise between aluminum plates.

Install SST (A) and (B) to the generator pulley with clutch as shown in the illustration.

GTY441544

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.

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.

GTY423540

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

*a	Turn
*b	Hold

Remove SST from the generator pulley with clutch.
Remove the generator pulley with clutch from the rotor shaft.

REMOVE GENERATOR ROTOR ASSEMBLY

Remove the generator rotor assembly.

GTY426597

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

INSPECT GENERATOR DRIVE END FRAME BEARING
See step 4

REMOVE GENERATOR DRIVE END FRAME BEARING

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

GTY146427

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Using SST and a hammer, tap out the generator drive end frame bearing.

GTY133160

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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