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Tackle the Rebuild Project

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Rebuild a Mitsubishi Alternator

From Ford to Subaru's Mitsubishi Manufactures the OEM Alternator for most all models. No solder required with this series for the basic Rebuild kit unless replacing / adding the SlipRing also.

Rebuilding a Denso Alternator:

You can find Hairpin Denso Alternators on BMW, Ford, GM, Honda, Toyota, and more. No solder required with most basic Rebuild kits unless replacing / adding the SlipRing also.


Step One:

-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.


Step Two:

-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.

Step Three:

-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).

Step Four:

-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).

Step Five:

-Carefully set aside your D3 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)

Step Six:

-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.

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