OEM 2004 Toyota 4Runner Alternator

2004 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2004 Toyota 4Runner?

  A: Start alternator repair or service by using Special Service Tool 09820-63010 (09820-06010 and 09820-06020) to remove the generator pulley by tightening SST 1-B to 39 Nm (400 kgf.cm and 29 ft.lbf) with a torque wrench while holding SST 1-A so that SST 1-B stays attached to the rotor shaft. Secure SST 2 to a vise while fitting SST 1-A and B inside SST 2 followed by attaching the pulley nut. Start by turning SST 1-A half a turn at the specified indicator point until a half turn limit is reached to prevent damage to the rotor shaft. After detaching SST 1-A and B from SST 2, remove the generator from the pulley using SST 1-A as a guide. Finally, uninstall the pulley nut and pulley to place the generator on the pulley and remove three nuts at the rear end. The terminal insulator removal should be followed by disassembling the generator brush holder assembly through plate seal removal and the two nut uninstallation. Proceed by unscrewing four bolts from the generator coil assembly then extract the coil using SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011). Remove the generator rotor assembly by discarding the washer and removing the rotor. Use vernier calipers to inspect the generator brush holder assembly and determine its exposed brush length must be within 4.5 mm - 10.5 mm (0.177 in. - 0.413 in.) or replacement is needed when lengths fall below the minimum threshold. Measuring slip ring open circuit resistance at 20 °C (68 °F) must result in 2.3 - 2.7 Ohms and slip rings should not have any electrical connection to the rotor. Determine slip ring smoothness and inspect for signs of scoring while checking that the diameter measures between 14.0 mm (0.551 in.) and 14.4 mm (0.567 in.); use new parts if the minimum is not met. If you detect either wear or roughness on the generator rotor bearing substitute it right away. Use SST 09820-00021 tool to remove the generator rotor bearing with caution for the fan and detach the bearing cover inside. The procedure for putting in the new generator rotor bearing starts by setting the rotor on the pulley while you install the bearing cover inside before applying SST 09820-00031 to push in the new bearing and finish with SST 09285-76010 for the outside bearing cover. Check for any roughness or wear on the generator drive end frame bearing before deciding on replacement. Use SST tools 09950-60010 (09951-00250) and 09950-70010 (09951-07100) to tap out the drive end frame bearing after removing its retainer plate using the four screws and its screws. A press must be used to install the new drive end frame bearing secured with SST 09950-60010 (09951-00470) and 09950-70010 (09951-07100). The retainer plate needs four screws to be tightened to a torque of 2.6 Nm (27 kgf.cm, 23 in.lbf). To reassemble the coil the technician should first place the drive end frame onto the rotor and then add the rotor and washer before pressing the coil using SST 09285-76010 and finally securing it with four bolts at 5.8 Nm (59 kgf.cm, 51 in.lbf). Install the brush holder assembly by placing the plate seal inside then secure it with two screws to a torque of 1.8 Nm while facing its pin upward before aligning the pins with the outside plate seal holes. Secure the terminal insulator along with the rear end cover in place by tightening three nuts to 4.6 Nm (47 kgf.cm, 41 in.lbf). To install the generator pulley follow these steps: first loosen the pulley nut manually then use a torque wrench to tight SST 1-B clockwise reaching 39 Nm (400 kgf.cm, 29 ft.lbf), secure SST to the rotor shaft. Place SST 2 in the vise and insert SST 1-A and B into it before applying the pulley nut. Tighten the nut by turning SST 1-A until it reaches 111 Nm (1,125 kgf.cm, 81 ft.lbf) torque, remove the generator from SST 2 and verify the pulley rotates effortlessly.