OEM 2001 Toyota Tundra Alternator

2001 Toyota Tundra Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2001 Toyota Tundra?

  A: Service and repair of an alternator starts from dismantling the device by first removing the rear end cover through terminal insulator and nut removal followed by bolt removal and finally taking off all 3 nuts, plate terminal and end cover. The first step entails the brush holder removal process which includes removing the screw and brush holder cover and 2 screws. The brush holder is followed by taking away the seal plate from the rectifier end frame. Beyond unscrewing three regulator screws you must remove the rectifier holder by unfastening four screws and four rubber insulators. Use Special Service Tool 09820-63011 with a torque wrench while holding the pulley with precision tooling that requires 39 Nm clockwise force (400 kgf.cm, 29 ft.lbf) until the rotor shaft achieves proper tool attachment. Place the adapter in a vise after inserting a socket with the pulley nut attached while counterclockwise twisting the nut less than a half turn to prevent rotor shaft damage. Disconnect the generator from the adapter before removing the socket and pulley holding tool and then the pulley nut and pulley. You must begin by disassembling the rectifier end frame through the removal of 4 nuts followed by utilizing Special Service Tool 09286-46011 to detach it. Proceed to remove the generator washer and rotor from the drive end frame. Reassembly starts with setting the rectifier end frame on the pulley followed by rotor attachment to the drive end frame and the rectifier end frame installation by placing the generator washer on the rotor while pressing in the frame with a 29 mm socket wrench and securing it with 4 nuts at 4.5 N.m (46 kgf.cm, 39 in.lbf). Before torquing the pulley tightly you first need to hand-tighten the nut then clamp the pulley using a tool with a torque wrench set at 39 N.m (398 kg.cm, 29 ft.lb). The tool must remain attached to the shaft of the pulley. Position the adapter in a vise while inserting the socket with a pulley nut which needs to be torqued to 111 N.m (1,132 kg.cm, 82 ft.lb). Remove the generator from the adapter before taking off both the socket and pulley holding tool from the installation. The procedure includes placing a rectifier holder with 4 rubber insulators on lead wires where correct direction matters before attaching a rectifier with 4 screws reaching 2.94 N.m torque (30 kgf.cm, 26 in.lbf). Place the seal plate first on the rectifier end frame before positioning the voltage regulator and brush holder. Use 5 screws to secure them at 1.96 N.m (20 kgf.cm, 17 in.lbf) after which you should cover the brush holder. Secure the end cover alongside its plate terminal by driving in the bolt and 3 nuts to 3.85 N.m while the terminal insulator requires a torque of 4.1 N.m before checking the rotor movement. Begin replacement of the front bearing by eliminating four screws after bearing retainer removal. Then apply Special Service Tool 09950-60010 (09951-00260, 09952-06010) for bearing extraction followed by bearing insertion using Special Service Tool 09950-60010 (09951-00520) prior to securing the bearing retainer with four screws at 3.0 N.m (31 kgf.cm, 27 in.lbf). Special Service Tool 09820-00021 enables the removal of rear bearing components from the bearing cover and bearing thus requiring extreme care to protect the fan before inserting the inside bearing cover onto the rotor followed by installing a new bearing using Special Service Tool 09820-00030 followed by using Special Service Tool 09285-76010 for the outside bearing cover installation.