OEM 2002 Toyota Tundra Alternator

2002 Toyota Tundra Alternator Parts Q&A

• Q: How to service and repair the alternator on 2002 Toyota Tundra?

  A: First service and repair procedures for the alternator start with removing the rear end cover by detaching its nut and terminal insulator followed by the bolt and three nuts then separating the plate terminal and end cover. First disconnect the brush holder by removing its cover followed by both screws then removing the holder itself before extracting the seal plate from the rectifier end frame. The voltage regulator needs three screws to be removed. Service position starts with nut and cord clip dissociation before proceeding to remove the 4 screws and rectifier holder followed by 4 rubber insulators. Special Service Tool 09820-63011 allows the torque wrench to hold the pulley before tightening the socket to reach 39 Nm (400 kgf.cm, 29 ft.lbf) clock-wise while ensuring the tool remains secured to the rotor shaft. The adapter needs to be secured in a vise before the socket goes inside while you attach the pulley nut and perform a slow counterclockwise rotation limiting shaft damage to less than half a turn. Proceed by taking the generator off the adapter and removing the socket then pulley holding tool before removing both the pulley nut and pulley. The process to take off the rectifier end frame starts by removing three nuts followed by tool use of Special Service Tool 09286-46011 to separate the components before you can remove the generator washer from the assembly. For assembly begin with placing the rectifier end frame onto the pulley and sliding in the rotor to the drive end frame and complete assembly with a 29 mm socket wrench to tighten 3 nuts to 4.5 N.m (46 kgf.cm, 39 in.lbf). First apply manual pressure to the pulley nut before using the pulley holding tool with a torque wrench for a 39 N.m (398 kg.cm, 29 ft.lb) tightening while verifying proper pulley shaft attachment. The generator gets unbolted from its adapter after the pulley nut reaches 111 N.m corresponding to 1,132 kg.cm and 82 ft.lb. Start by installing the correct direction rubber insulation on the rectifier holder with four pieces before tightening the rectifier with four screws at 2.94 N.m (30 kgf.cm, 26 in.lbf) and the cord clip with its nut at 5.4 N.m (55 kgf.cm, 48 in.lbf). Install the seal plate on the rectifier end frame before adding the voltage regulator along with the brush holder and fasten them using 5 screws at 1.96 N.m (20 kgf.cm, 17 in.lbf). Complete the installation by covering the brush holder. The rear end cover requires installation of both the end cover along with plate terminal using a bolt and three nuts at 3.85 N.m (39 kgf.cm, 34 in.lbf) and the terminal insulator using a nut at 4.1 N.m (41.5 kgf.cm, 36 in.lbf) while ensuring rotor smooth rotation. Switching out the front bearing involves first removing four screws coupled with the bearing retainer and subsequently pressing out the bearing using Special Service Tool 09950-60010 (09951-00260, 09952-06010) to install a fresh bearing with identical tool usage and reattaching the bearing retainer by screw sequences at 3.0 N.m (31 kgf.cm, 27 in.lbf). Replace the rear bearing by using Special Service Tool 09820-00021 to detach the bearing cover followed by the bearing then install an inside bearing cover onto the rotor before pressing in a new bearing through Special Service Tool 09820-00031 followed by using the outside bearing cover with tool 09285-76010.