OEM 2006 Toyota Tundra Alternator

2006 Toyota Tundra Alternator Parts Q&A

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

  A: A first step for alternator repair requires using SST 09820-63011 to remove the generator pulley before securing SST (A) with a torque wrench and tightening SST (B) clockwise to 39 N.m (400 kgf.cm, 29 ft.lbf). Make sure SST stays safely attached to the rotor shaft. At first position SST 2 into a vise before inserting SST (A) and (B) into SST (C) then connect the pulley nut to SST (C). Screw SST (A) while turning it following the indicated direction yet stop the rotation before reaching one half turn because excessive movement will damage the rotor shaft. When completed, remove the generator from SST (C) and remove SST (A) and (B). Proceed by keeping the generator on the pulley to remove the 3 nuts and finally the generator rear end cover. Initial the process of removal by dismounting the terminal insulator together with the generator brush holder assembly through plate seal detachment and removal of the two nuts. Extract the generator coil assembly with SST 09950-40011 that includes instruments 09951-04020, 09952-04010, 09953-04020, 09954-04010, 09955-04071, 09957-04010, 09958-04011 while removing the four bolts from their housing. The generator rotor assembly requires removal of both washer and rotor component. An ohmmeter should be used to inspect the rotor's slip ring open circuits and continuity while confirming standard resistance between 2.3 to 2.7 Ohms at 20 degrees Celsius (68 degrees Fahrenheit). Replacing the rotor is necessary when continuity tests show no results. The slip ring must show ground continuity with the rotor while slip rings need examination for roughness and scoring that requires replacing the rotor if found. Check the slip ring diameter using vernier calipers to verify it falls between 14.2 to 14.4 mm (0.559 to 0.567 in.) but never less than 14.0 mm (0.551 in.). To inspect brushes measure their exposed length because it must be at least 4.5 mm (0.177 in.) before replacement of brush holder assembly when below this threshold. Replace any damaged bearing components after checking severity of wear marks. The generator rotor bearing should be inspected before replacement to ensure it is not damaged and removed carefully through SST 09820-00021 while protecting the fan. The new bearing should be installed by first fitting the rotor onto the pulley then applying the bearing cover before using SST 09820-00031 to press in the new bearing until SST 09285-76010 pushes the bearing cover into position. The drive end frame bearing of the generator gets checked for roughness or wear through a procedure that begins with unscrewing the four screws and retainer plate and finishes with tapping it out using SST 09950-60010 (09951-00250) or 09950-70010 (09951-07100). Utilize the SST to install a bearing by pressing then reinstall the retainer plate with its four screws tightened to 2.6 N.m (27 kgf.cm, 23 in.lbf). The generator rotor assembly needs to be installed by positioning the drive end frame on the rotor before installing both the rotor and washer. Press the generator coil assembly with care using SST 09285-76010 before installing and tightening the 4 bolts to 5.8 N.m (59 kgf.cm, 51 in.lbf). The installation requires placing the plate seal inside before you position the brush holder pin upward and secure two screws to 1.8 N.m (18 kgf.cm, 16 in.lbf) while aligning the pins to the outside of the plate seal. Secure the generator rear end cover to the terminal insulator by using 3 nuts and tightening them to 4.6 N.m (47 kgf.cm, 41 in.lbf). SST 09820-63011 serves to install the generator pulley through hand-tightening the pulley nut followed by torque wrench usage to turn SST (A) while tightening SST (B) clockwise until reaching 39 N.m (400 kgf.cm, 29 ft.lbf). Confirm SST (B) remains securely engaged to the rotor shaft. SST (C) must be clamped in place before inserting SST (A) and (B) while adjusting the pulley nut through SST (A) until it reaches 111 N.m (1,125 kgf.cm, 81 ft.lbf). The generator should then be taken out of SST (C) and SST (B) removed to verify smooth pulley rotation.