-Remove the Rectifier Cover. Held in place by Flanged Nuts.
On this model they are easily removed with an 8mm socket.
Revealing the Rectifier (see below).
NOTE: If purchasing a repair kit, all hardware (screws, nuts, and bolts) are sold separately..
-Remove the Brush Holder Screws surrounding the Brush Holder and the Voltage Regulator
-Then remove the Brush Holder and Voltage Regulator
NOTE: Be sure to dedicate a spot for screws and parts you are not replacing to ensure they do not get lost.
-Remove the Pulley.
-On this models it is held on by a single Hex Nut
Removed easily with a 24mm socket.
Addition parts not listed: Brushes, not seen in pictures, brushes are inside the brush holder and 2 “spares” are conveniently supplied with each purchase of a brush holder or repair kit (that includes a brush holder).
-Remove 4 Thru-Bolts that are surrounding the rectifier, holding the frame/case together.
Removed easily with an 8mm socket.
-Then, seperate the DE Frame (half with the pulley) from the SRE Frame (half with the rectifier).
-Carefully set aside your DE Frame and remove the Rotor from the SRE Frame.
-In the picture to the right we have a lip surrounding the Slip Ring, Bearing, and Bearing Cover.
If this is the case on your alternator go ahead and cut then bend back the lip to allow access under the bearing. (you will need to do this on both sides of the slip ring)
-Our mechanic uses 2 flathead screwdrivers and a simple leverage technique, applying equal pressure to both sides, to force the bearing cap, bearing, and rotor shaft spacer off of the slip ring.
NOTE: If you have to cut and bend the lip on the rotor be sure the grooves are exactly across from each other AND NOT OVER THE SLIP RING LEADS to ensure the slip ring does not bend while putting pressure on the bearings.
To see more, please click on one of the following links:
PDF Rebuilding Denso Alternator Instructions [part 2, reassembly]. Or, Video Tutorial.
PDF How to Replace the Brushes. Or, Video Tutorial.
PDF Rebuilding Denso Slip Ring Instructions. Or, Video Tutorial.