OEM 2006 Toyota 4Runner Alternator

2006 Toyota 4Runner Parts Questions & Experts Answers

• Q: How to overhaul the alternator assembly on 2006 Toyota 4Runner?

  A: Special Service Tool 09820-63010 (09820-06010, 09820-06020) allows generator assembly pulley removal through the following steps: hold the pulley holding tool with a torque wrench before tightening the socket in a clockwise direction up to 39 Nm (400 kgf.cm, 29 ft.lbf). The tool needs to remain fixed to the rotor shaft. The adapter goes into a clamp fixture next before both socket insertion and pulley nut installation where you should only turn the nut clockwise for less than one-quarter rotation to avoid rotor shaft damage. Begin generator adapter pulley removal by taking off the generator from the adapter before removing its pulley nut and pulley. Position the generator on the pulley first then detach the rear end cover and three nuts and terminal insulator together and generator brush holder assembly by taking out the plate seal and two holding nuts. The generator coil assembly requires four bolt removal with Special Service Tool 09950-40011 (which includes 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011) to complete the coil detachment. Move the washer and rotor from the assembly before using vernier calipers to measure the generator brush holder assembly. Verify the brush length falls between 4.5 mm (0.177 in.) and 10.5 mm (0.413 in.). Open circuit resistance must be measured between the slip rings because it should be 2.3 - 2.7 Ohms at 20°C (68°F) while slip ring to rotor continuity should be non-existing. Check that slip ring diameters lie between 14.0 mm (0.551 in.) and 14.4 mm (0.567 in.) while monitoring them for rough surface areas and scoring. Use Special Service Tool 09820-00021 to remove the generator rotor bearing while protecting the fan from damage during the procedure. The generator requires Special Service Tool 09820-00031 and Tool 09285-76010 to properly insert the new bearing while first putting the rotor on the pulley then installing the bearing cover inside before pressing in the new bearing with ST 09820-00031 and pushing in the bearing cover outside with ST 09285-76010. During replacement of a newly acquired drive end frame bearing inspect the generator bearing for wear and tighten its retainer plate using four screws when secured to 2.6 N.m (27 kgf.cm, 23 in.lbf) torque. Reassembly begins with placing the drive end frame on the rotor then adding the rotor with washer while using Special Service Tool 09285-76010 to press the coil before securing with four bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf). Install the brush holder assembly after verifying the plate seal placement then fasten it with 1.8 N.m (18 kgf.cm, 16 in.lbf) torque through two screws. Reassemble the unit by attaching the drive end frame to the rotor and installing the rotor with a washer before using Special Service Tool 09285-76010 to press in the coil and securing four bolts to 5.8 N.m (59 kgf.cm, 51 in.lbf). Next install the brush holder assembly with a plate seal correctly placed and secure it with two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf). Finally, install the terminal insulator followed by three nuts tightening the rear end cover to 4.6 N.m (47 kgf.cm, 41 in.lbf),and the pulley by tightening the pulley nut by hand, then using the pulley holding tool to tighten it to 39 Nm (400 kgf.cm, 29 ft.lbf) and subsequently to 111 Nm (1,125 kgf.cm, 81 ft.lbf), ensuring the pulley moves smoothly.