OEM 2004 Toyota Tundra Alternator

2004 Toyota Tundra Parts Questions & Experts Answers

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

  A: Service and repair of the alternator starts with component disassembly which involves removing the rear end cover by detaching the nut and terminal insulator then the bolt and the 3 nuts and plate terminal and end cover before removing the brush holder cover from the brush holder. You should start by taking out the brush holder after unscrewing its 2 screws then removing the seal plate from the rectifier end frame. The voltage regulator needs three screws removed. The process of removing the rectifier holder requires both 4 screws and 4 rubber insulators to be removed. Install Special Service Tool 09820-63011 onto the torque wrench then use it to fasten the pulley socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf) while securing the tool on the rotor shaft. Set the adapter inside a vise in which the socket mounts. After putting the pulley nut onto the adapter, use the counterclockwise motion to loosen the nut but avoid more than a half turn to ensure rotor shaft protection. The generator needs to be separated from the adapter before removing the socket, pulley holding tool and then the pulley nut and pulley. The rectifier end frame removal process begins by removing the four nuts then using Special Service Tool 09286-46011 to separate it from the generator while wiping away the generator washer. Place the rectifier end frame on the pulley before installing the rotor to drive end frame followed by placement of the generator washer on the rotor. Then use a 29 mm socket wrench to torque in the rectifier end frame at 4.5 N.m with 4 nuts applied at 4.5 N.m (46 kgf.cm, 39 in.lbf). Use hand power to tighten the pulley nut before using the pulley holding tool to apply clockwise torque of 111 N.m (1,132 kg.cm, 82 ft.lb). Detach the generator from both the power adapter along with the socket and the pulley holding device. Place 4 rubber insulators onto the lead wires until they sit properly on the rectifier holder then fasten the rectifier with 4 screws according to the torque specification of 2.94 N.m (30 kgf.cm, 26 in.lbf). Fasten the voltage regulator and brush holder by putting the seal plate on the rectifier end frame before tightening the 5 screws to 1.96 N.m (20 kgf.cm, 17 in.lbf). Following the brush holder cover placement on its holder you must attach the end cover with a bolt and three nuts tightened to 3.85 N.m (39 kgf.cm, 34 in.lbf) and the plate terminal with 4.4 N.m (46 kgf.cm, 39 in.lbf) followed by terminal insulator attachment using the nut at 4.1 N.m (41.5 kgf.cm, 36 in.lbf). The rotor needs to move without any disruptions during rotations.