OEM 2004 Toyota Sequoia Alternator

2004 Toyota Sequoia Alternator Parts Q&A

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

  A: Begin service and repair of the alternator by first removing the rear end cover through the process of taking off the 3 nuts and end cover. Next remove the terminal insulator. Start by removing the brush holder through unscrewing two screws on it. Before securing the pulley holding tool (Special Service Tool 09820-63011) fit it onto the rotor shaft and lock the torque wrench at 39 Nm (400 kgf.cm, 29 ft.lbf). After placing the adapter in a vise position the socket and pulley nut, use the tool to turn the pulley nut counterclockwise while avoiding half turn rotation to prevent rotor shaft damage. Separate the generator from the adapter before removing the socket and pulley holding tool as well as the pulley nut and pulley. Screw off the 4 bolts before using Special Service Tool 09950-40011 and its parts to extract the coil assembly and then remove the generator washer. Replacing the front bearing requires unscrewing four screws along with the bearing retainer before tapping out the bearing with Special Service Tool 09950-60010 (09951-00250) while pushing in a new bearing with Special Service Tool 09950-60010 (09951-00470) and 09950-70010 (09951-07100). The reassembly process concludes with screwing in the bearing retainer at a torque of 2.6 N.m (27 kgf.cm, 23 in.lbf). First remove the bearing cover together with the bearing by using Special Service Tool 09820-00021 and replace them with a new bearing through operator use of Special Service Tool 09820-00031 and finish the process by pushing in the bearing cover using Special Service Tool O9285-76O10. Reassembly of the rotor starts with installing it to the drive end frame followed by positioning the generator washer on the rotor before pressing in the coil assembly with Special Service Tool O9285-76O10 while securing it with 4 bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf). Install the pulley while starting the nut by hand before using the pulley holding tool (Special Service Tool 09820-63011) to torque it to 39 N.m (398 kg.cm, 29 ft.lb) with assurance of proper pulley shaft attachment. Fix the adapter in a vise before installing the pulley nut then apply torque of 111 N.m (1,132 kg.cm, 82 ft.lb) to it. The generator must be separated from its adapter before the socket holder can be removed and the pulley tool. Set the brush holder onto the coil assembly with the pin pointing upward while installing 2 screws that need to be torqued to 1.8 N.m (18 kgf.cm, 16 in.lbf). Secure the terminal insulator and end cover by tightening 3 nuts to 4.6 N.m (47 kgf.cm, 41 in.lbf) with the requirement for rotor movement without resistance.