OEM 2005 Toyota Tacoma Alternator

2005 Toyota Tacoma Parts Questions & Experts Answers

• Q: How to overhaul the alternator on 2005 Toyota Tacoma?

  A: The process of alternator overhaul requires using Special Service Tool 09820-63010 (09820-06010, 09820-06020) to remove the pulley through a sequence of steps. The holding tool must be tightened with a torque wrench at 39 Nm (400 kgf.cm, 29 ft.lbf) to the rotor shaft. Following pulley nut counterclockwise motion until achieving only a halfturn rotation prevents rotor shaft damage before you detach the generator adapter and finally remove the pulley nut together with the pulley. Begin by removing the generator brush holder assembly when you have unscrewed the nut and terminal insulator before proceeding to take off the rectifier plate and rear end cover and brush cover. After that detach the generator regulator assembly by unfastening its two screws. Begin by removing the three screws from the generator rectifier holder until it can be removed. Then extract the generator rotor assembly after unscrewing its terminal insulators and nuts and using Service Tool 09286-46011 to detach the rectifier end frame and doing so without dropping the rotor. Examine the generator brush holder assembly to verify brush exposure falls between 9.5 to 11.5 mm and schedule replacement if brush length reaches less than 4.5 mm. Continuity testing of the generator regulator assembly between terminals F and B and F and E must be as specified and replacement is needed in case of non-compliance. Test the generator rectifier holder for electrical connections between P1 P2 P3 P4 and B and E terminals and change it when necessary. Realize the resistance between slip rings in the generator rotor assembly should remain within 1.7 - 2.1 Ohms and check for slip ring to rotor assembly continuity with a replacement if any connection exists. The rotor assembly requires replacement if the slip ring roughness exists or its diameter measures less than 14.0 mm. The installation of the generator rotor assembly requires first placing the drive end frame onto the assembly followed by pressing in the rectifier end frame before securing it with four nuts using 4.5 N.m torque (46 kgf.cm, 40 in.lbf). Use 2.0 N.m of torque to install three screws on the generator rectifier holder before proceeding to secure the generator regulator assembly with two screws at the same torque. After installing the generator brush holder assembly with three screws at 2.0 N.m (20 kgf.cm, 17 in.lbf), fix the plate seal then connect the brush cover and rear end cover through two nuts at 4.4 N.m (45 kgf.cm, 39 in.lbf) before securing the rectifier plate with proper torque values. The generator pulley requires hand installation while a pulley holding tool should be used to tighten the pulley nut to 39 Nm (400 kgf.cm, 29 ft.lbf) before increasing the torque to 111 Nm (1,125 kgf.cm, 81 ft.lbf). Ensure the pulley shows proper movement after removing it from the adapter.