Toyota 27060-0P141-84
Reman Alternator

Begin the alternator overhaul process by eliminating the generator with clutch pulley while using a screwdriver to detach the generator pulley cap and inserting SST (A) and (B) equipped with SST 09820-63020 to position the rotor shaft onto SST (A) before securing it in a vise. Install the generator using the SST while you rotate SST (B) clockwise to loosen the generator pulley thus removing both components from SST and the rotor shaft. Afterward you should remove 3 nuts prior to removing the generator rear end cover along with the terminal insulator. To access the generator brush holder assembly the technician must remove the two screws before they can take off the generator coil assembly through four bolts with SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) tool followed by the removal of the generator washer. Remove all parts from the generator rotor assembly. Check that the clutch pulley of the generator turns counterclockwise only without experiencing clockwise rotation. Use vernier calipers to measure the exposed brush length of the generator brush holder assembly and verify that the length satisfies 10.5 mm (0.413 in.) and exceeds 4.5 mm (0.177 in.) and if not replace with a new part. DEL will inspect the generator rotor assembly bearing for irregularities or wear and will replace it if essential and will test the slip ring resistance at 20 degrees Celsius with an ohmmeter to check it stays between 2.3 to 2.7 Ohms; any results failing will require replacement. To check for short circuits perform two tests: measure the 1 MOhm or higher resistance between each slip ring and rotor and determine the slip ring diameter falls between 14.2 to 14.4 mm (0.559 to 0.567 in.) with a minimum of 14.0 mm (0.551 in.). Replacement is needed if minimums are not met. Check for wear or roughness on the drive end frame bearing of the generator and replace it as needed. The bearing removal process for the generator drive end frame requires the removal of bearing retainer screws and SST utility with 09950-60010 (09951-00250) and 09950-70010 (09951-07100) for tapping it out using an SST hammer. To put in a new generator drive end frame bearing, begin by inserting it with SST 09950-60010 (09951-00470) and 09950-70010 (09951-07100) while using a press tool. Finish with bearing retainer installation through the use of 4 screws that should be torqued to 2.3 N.m (23 kgf.cm, 20 in.lbf). Slowly push the generator coil assembly into the drive end frame structure with a deep 21 mm socket wrench which should be activated by a press tool to secure it through four bolt screws torqued up to 5.8 N.m (59 kgf.cm, 51 in.lbf). The generator brush holder assembly requires two brush compressions followed by a 1.0 mm (0.039 in.) pin insertion into the generator brush holder hole. The next step is to install both screws at 1.8 N.m (18 kgf.cm, 16 in.lbf) while keeping the pin in position until it is removed. The terminal insulator requires proper orientation before you install it and then you can add the rear end cover with the three nuts torqued to 4.6 N.m (47 kgf.cm, 41 in.lbf). Utilize SST (A) and (B) for this step while positioning SST (A) in the vise to start installation of the generator on the SST. Rotate SST (B) clockwise until the generator pulley reaches 87 N.m (891 kgf.cm or 64 ft.lbf) using a torque wrench set at 380 mm (14.96 in.). After generator removal from the SST inspections must demonstrate smooth generator pulley rotation and the new generator pulley cap must be installed.

A proper alternator repair requires generator removal together with the clutch pulley. The screwdriver removes the generator pulley cap while you should set the rotor shaft to use Rotor Shaft Holding Tool (SST: 09820-63020). Secure this tool in a vise. The Special Service Tool allows you to install the generator counterclockwise while turning the Clutch Pulley Wrench clockwise to remove the generator from the SST before removing the pulley from the rotor shaft. The procedure starts with removing the 3 nuts and generator rear end cover before extracting the terminal insulator. Continue by undoing the 2 screws that secure the generator brush holder assembly followed by the generator coil assembly that requires removal of the 4 bolts before detaching it with SST. Finish the process by removing the generator washer. Then separate the generator rotor and proceed with removing the drive end frame bearing through the removal of 4 screws and bearing retainer. Finally use Special Service Tools along with a hammer to extract the bearing (SST: 09950-60010, 09951-00250, SST: 09950-70010, 09951-07100).

Disconnect the wire harness clamp, remove the terminal cap, and then remove the nut to disconnect the wire harness from terminal B.

Remove the terminal cap and then remove the nut to disconnect the wire harness from terminal B.

Remove the nut from the cylinder block.

Remove the V-ribbed belt.

Place the generator assembly on the clutch pulley and remove the 3 nuts and rear end cover.

Secure the bracket with a bolt, torqued to 20 N.m (204 kgf.cm, 15 ft.lbf).

Install the terminal insulator ensuring correct orientation, followed by the rear end cover with 3 nuts torqued to 4.6 N.m (47 kgf.cm, 41 in.lbf).

Start by removing the generator clutch pulley by puncturing the center of the generator pulley cap with a screwdriver and prying it off, ensuring not to reuse the cap.

Remove the front right wheel.

Torque it to 8.4 N.m (86 kgf.cm, 74 in.lbf).

Disconnect the cable from the negative battery terminal, noting that some systems may require initialization after reconnection.

Use a wrench to hold the Rotor Shaft Holding Tool while turning the Clutch Pulley Wrench counterclockwise, ensuring the drive end frame is secured tightly in the vise.

Connect the cable to the negative battery terminal, noting that some systems may require initialization after reconnection.