OEM 2003 Toyota Tacoma Alternator

2003 Toyota Tacoma Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2003 Toyota Tacoma?

  A: The servicing process for an alternator begins with rear end cover removal through the sequence of terminal insulator and nut detachment followed by end cover and three nuts deinstallation. To begin servicing the alternator start by removing the brush holder and voltage regulator by taking out five screws. Take out the rectifier holder after removing its bolt then its four screws. After holding SST (A) with a torque wrench you should apply SST (B) with a clockwise motion to achieve 39 N.m (400 kgf.cm, 29 ft.lbf) torque while ensuring SST (A) remains fixed to the rotor shaft. Screw the generator to SST (C) while secure SST (C) to a vise then turn SST (A) until the pulley nut achieves loose threading but maintain less than half rotation to protect the rotor shaft. First detach the generator from SST (C) before turning SST (B) to separate SST (A and B) and finally unfasten the pulley nut and pulley. The procedure to remove the rectifier end frame begins by detaching it with SST 09286-46011 after removing its four nuts. The drive end frame should be placed on the pulley before installing the rotor and rectifier end frame by placing the generator washer on the rotor and pressing the rectifier end frame with a 29 mm socket wrench and tightening four nuts to 4.5 N.m (46 kgf.cm, 40 in.lbf). Secure the pulley shaft with hand-tightening of the pulley nut before torquing SST (A) with a torque wrench which leads to SST (B) reaching 39 N.m (400 kgf.cm, 29 ft.lbf) and confirming that SST (A) is properly fastened to the pulley shaft. Torque SST (C) to a vise before you install the generator and then apply 110 N.m (1,125 kgf.cm, 81 ft.lbf) to the pulley nut before finally detaching the generator from SST (C) and removing SST (A and B). Module the rectifier holder by tightening its bolt to 3.9 N.m (40 kgf.cm, 34.7 in.lbf) while screw bolts require 1.96 N.m (20 kgf.cm, 17.4 in.lbf) torque. Position the voltage regulator horizontally while installing it on the rectifier end frame before tightening its five screws to achieve a 1 mm (0.04 in.) gap between the brush holder and connector while torquing up to 1.96 N.m (20 kgf.cm, 17.4 in.lbf). Install the rear end cover using nuts that receive 4.5 N.m (46 kgf.cm, 40 in.lbf) torque. Before installation, check the rotor steadily rotates. Lastly, place a nut on the terminal insulator then tighten it to 4.1 N.m (42 kgf.cm, 36 in.lbf). Begin by removing the brush and spring then feed new brush wire into the spring as well as the brush holder's hole. Finally solder this wire with 9.5-to-11.5 mm (0.374 - 0.453 in.) exposed length and check brush movement before trimming the remaining wire and applying insulation paint. The procedure involves removing four screws and the bearing retainer and bearing before using press tools SST 09950-60010 (09951-00260, 09952-06010) to remove the old bearing and SST 09950-60010 (09951-00500) for installing the new bearing securely with screws at 2.6 N.m (26.5 kgf.cm, 23 in.lbf). Apply SST procedures to remove the bearing cover and bearing from the rear position while being cautious of fan damage. Subsequently install the inside bearing cover onto the rotor prior to using SST 09820-00030 to press in a fresh bearing and finally use SST 09285-76010 to install the outside bearing cover.