OEM 2005 Toyota Tundra Alternator

2005 Toyota Tundra Parts Questions & Experts Answers

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

  A: The alternator repair procedure starts with generator pulley removal by using Special Service Tool 09820-63011; install the pulley holding tool onto the torque wrench set at 39 Nm (400 kgf.cm, 29 ft.lbf) while making sure the tool grips the rotor shaft. Before fitting the adapter to the vise you must align the socket into the adapter shaft while attaching the pulley nut. Perform this step by turning the holding tool counterclockwise to prevent rotor shaft damage and avoid exceeding a half turn. Unplug the generator from its adapter while you disconnect the socket alongside the pulley holding tool and afterward remove the pulley nut and pulley. Position the generator on the pulley before removing the three nuts along with the rear end cover and continuing to detach the terminal insulator along with the generator brush holder assembly by removing the plate seal and the two nuts. To extract the generator coil assembly remove the four bolts then utilize Special Service Tool 09950-40011 (inclusive tools) to release the coil before removing the generator rotor assembly by separating washer and rotor. With the ohmmeter test rotor slip rings for standard continuity and verify 2.3 to 2.7 Ohms resistance at 20 °C (68 °F); if no continuity is detected the rotor needs replacement. A continuity check between rotor's slip rings and rotor base must happen. If you find any ground effect replace the rotor immediately. Check the slip ring has no rough or scored surface and measure its diameter with vernier calipers against 14.2 to 14.4 mm (0.559 to 0.567 in.) specifications that must exceed the minimum of 14.0 mm (0.551 in.) else replace the rotor. An inspection of exposed brush length should measure at least 4.5 millimeters (0.177 inches); insufficient measurements require new brushes and brush holders. Check for bearing surface roughness and wear before deciding on a new replacement. Special Service Tool 09820-00021 allows you to remove the generator rotor bearing through its process while ensuring fan safety. The procedure for bearing replacement includes mounting the rotor onto the pulley before adding the bearing cover followed by usage of Special Service Tool 09820-00031 to press in the new bearing before using Special Service Tool 09285-76010 to push in the bearing cover. Check the generator drive end frame bearing for wear or rough condition before removing it with Special Service Tool 09950-60010 (09951-00250) or 09950-70010 (09951-07100) by first unscrewing four screws and retainer plate. The installation requires Special Service Tool 09950-60010 (09951-00470) or 09950-70010 (09951-07100) for inserting a new bearing while ensuring retainer plate screws are tightened to 2.6 N.m (27 kgf.cm, 23 in.lbf). Insert the drive end frame onto the rotor followed by installing the rotor and washer before using Special Service Tool 09285-76010 to press in the coil which should be secured with four bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf). Start by inserting the plate seal inside, then position the brush holder pin upward and use two screws to tighten them at 1.8 N.m (18 kgf.cm, 16 in.lbf). Next, align the brush holder pins with the plate seal holes before installing the outside plate seal. After applying the terminal insulator, users should install the rear end cover by tightening three nuts to 4.6 N.m (47 kgf.cm, 41 in.lbf). The generator pulley installation process demands the usage of Special Service Tool 09820-63011 to begin with hand-tightened pulley nut operation and subsequent torque wrench application until achieving 39 Nm (400 kgf.cm, 29 ft.lbf) while keeping the tool firmly on the pulley shaft. Afterwards, clamp the adapter within a vise, insert the socket before applying the pulley nut and reaching 111 Nm (1,125 kgf.cm, 81 ft.lbf) torque before generator adapter removal for pulley smoothness verification.