OEM 2005 Toyota 4Runner Alternator

2005 Toyota 4Runner Alternator Parts Q&A

• Q: How to overhaul the alternator assembly on 2005 Toyota 4Runner?

  A: Overhauling the generator assembly begins with removing the generator pulley through the use of SST 09820-63010 (09820-06010, 09820-06020). SST 1-A requires support from a torque wrench that tightens SST 1-B clockwise to 39 N.m (400 kgf.cm, 29 ft.lbf) strength until SST fully anchors to the rotor shaft. Secure SST 2 in a vise before placing SST 1-A and B inside it while attaching the pulley nut. The operator should turn SST 1-A to loosen the pulley nut while avoiding more than a half turn to safeguard the rotor shaft, then remove the generator from SST 2 while detaching SST 1-A and B. To begin next step the pulley nut and pulley must be removed followed by the rear end cover once the generator is installed on the pulley and the three nuts are detached. Remove the terminal insulator as well as the generator brush holder assembly by dislodging the plate seal and each of the two nuts. Unscrew the 4 bolts securing the generator coil assembly after which SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) can be used to extract the coil. Next proceed to remove the generator rotor assembly after uncoupling its washer and rotor. Verify the exposed brush length of the generator brush holder assembly using vernier calipers to confirm proper dimensions which must be at least 10.5 mm (0.413 in.) yet not less than 4.5 mm (0.177 in.). An ohmmeter should measure between 2.3 - 2.7 Ohms at 20°C (68°F) for the open circuit resistance between slip rings inside the generator rotor assembly. Additionally check that there is no electrical connection between the slip rings and rotor. Slip rings require an examination to detect roughness or scoring while their diameters should measure between 14.2 - 14.4 mm (0.559 - 0.567 in.) without going below 14.0 mm (0.551 in.). The generator rotor bearing should be tested for roughness or wear and requires replacement when necessary. Use SST 09820-00021 to extract the generator rotor bearing from its position while protecting the fan mechanisms and afterward eliminate the bearing cover (from inside). To install the new generator rotor bearing proceed by placing the rotor on the pulley then install the bearing cover (inside) before pressing the new bearing into place with SST 09820-00031 and pushing in the bearing cover (outside) with SST 09285-76010. The generator drive end frame bearing requires examination for surface damage and wear before installation of a new one. You can strip down the bearing by removing four screws and the retainer plate and tapping it out using SST 09950-60010 (09951-00250), SST 09950-70010 (09951-07100). Use the required tools (SST 09950-60010 (09951-00470) and 09950-70010 (09951-07100)) to install a new drive end frame bearing and fasten it with 4 screws which should be torqued to 2.6 N.m (27 kgf.cm, 23 in.lbf). To reassemble the application start by mounting the drive end frame onto the rotor before adding the rotor and washer and using SST 09285-76010 to press in the coil and securing it with 4 bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf). Mount the brush holder using the plate seal (inside) and confirm proper orientation before tightening two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf). The installation should have pins on the brush holder align with the plate seal (outside). The terminal insulator and rear end cover should go together with 3 nuts while torquing to 4.6 N.m (47 kgf.cm, 41 in.lbf). Fit the generator pulley by first manually tightening the pulley nut before applying torque through SST 1-A to SST 1-B in a clockwise direction up to 39 N.m (400 kgf.cm, 29 ft.lbf) until SST securely engages the rotor shaft. Afterward, place SST 2 into a vise followed by insertion of SST 1-A and B into SST 2 before attaching the pulley nut. Twist SST 1-A clockwise to reach 111 N.m (1,125 kgf.cm, 81 ft.lbf) torque while removing the generator from SST 2 and finally checking that the pulley moves smoothly.