OEM 2006 Toyota RAV4 Alternator

2006 Toyota RAV4 Parts Questions & Experts Answers

• Q: How to service and repair the alternator on 2006 Toyota RAV4?

  A: The repair process begins with generator pulley and clutch removal after properly puncturing and prying away the cap with a screwdriver and discarding it for new usage. The first step is to mount Special Service Tool 09820-63020 along with a vise to the pulley before attaching the Rotor Shaft Holding Tool to a vise. The Clutch Pulley Wrench needs to turn clockwise to remove and loosen the pulley. Start by disconnecting the generator brush holder assembly which requires removal of 3 nuts and a rear end cover before unfastening the terminal insulator and its 2 securing screws. The generator rotor assembly requires removal of its bolt and cord clip followed by 4 bolts which require SST 09950-40011 (09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010) to extract the coil before proceeding to the washer and rotor. Reassembly starts with mounting the washer onto the generator rectifier end frame before inserting the generator rotor. A 32 mm socket wrench and press should now ease the generator drive end frame into the rectifier end frame while securing the 4 bolts at 5.8 N.m (59 kgf.cm, 51 in.lbf) and using the bolt to lock the cord clip at 4.6 N.m (47 kgf.cm, 41 in.lbf). To install the generator brush holder assembly first push the two brushes into the holder before inserting a 1.0 mm (0.039 in.) pin which will be removed when securing the holder with two screws at 1.8 N.m (18 kgf.cm, 16 in.lbf). The terminal insulator should be installed onto the rectifier end frame, followed by tightening the rear end cover with 3 nuts at 4.6 N.m (47 kgf.cm, 41 in.lbf). Finish the installation by first hand-mounting the generator pulley with clutch then usage of Special Service Tool 09820-63020 in a vise secures the pulley before turning it counterclockwise at 111 N.m (1125 kgf.cm, 81 ft.lbf). Complete with a new cap while double-checking the smooth rotation of the generator pulley.