OEM 2005 Toyota Sequoia Alternator

2005 Toyota Sequoia Alternator Parts Q&A

• Q: How to service and repair the alternator on 2005 Toyota Sequoia?

  A: Start the alternator repair process by following this sequence: remove the rear end cover by unfixing the 3 nuts and terminal insulator and later detach the brush holder using screw removal from its 2 screws. Apply Special Service Tool 09820-63011 with its torque wrench to secure the tool onto the rotor shaft through pulley holding tool while tightening the socket clockwise to 39 Nm (400 kgf.cm, 29 ft.lbf). By using the vise assembly hold the adapter and insert the socket into it. Install the pulley nut and loosen it shy of half a turn in a counterclockwise direction to prevent damage to the rotor shaft. Begin by disconnecting the generator from the adapter before removing the socket and pulley holding tool that will subsequently be followed by the pulley nut and pulley. The coil assembly requires removal by first removing 4 bolts and applying Special Service Tool 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09958-04011) to separate it before removing the generator washer. The first step for replacement begins with the front bearing removal process that requires uninstalling four screws before removing the bearing retainer and bearing. Special Service Tools 09950-60010 (09951-00250) and 09950-70010 (09951-07100) will help tap out the bearing from its position before installation. The new bearing needs press fitting followed by 4 screw reinstallation of the bearing retainer which requires torquing up to 2.6 N.m (27 kgf.cm, 23 in.lbf). Remove the bearing cover and bearing from the rear section by using Special Service Tool 09820-00021 before pressing in a new bearing with Specific Service Tool 09820-00031 then installing the bearing cover using Special Service Tool 09285-76010. To rebuild the rotor you should first mount it onto the drive end frame before adding the generator washer and inserting the coil assembly with Special Service Tool 09285-76010 until it is secured with 4 bolts torqued to 5.8 N.m (59 kgf.cm, 51 in.lbf). The pulley holding tool (Special Service Tool 09820-63011) should be used to tighten the pulley nut which must reach 39 N.m (398 kg.cm, 29 ft.lb) then torque it to 111 N.m (1,132 kg.cm, 82 ft.lb). Fix the brush holder so the pin points up while tightening its two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf). Next, put on the terminal insulator followed by the end cover secured by torquing three nuts to 4.6 N.m (47 kgf.cm, 41 in.lbf). The final step requires inspection of smooth rotor spin.