Gen 2 Alternator

[jefe]

Here is some info. on my alternator experience that may be helpful. Hopefully someone can learn from my mistake(s!) I ended up damaging my alternator and ultimately had to buy a rebuilt one. (It was $120 at NAPA after core swap.)

Not sure if anyone read my thread about the problems I was having...
http://www.toyotanation.com/forum/t62995.html

My intent was to try to replace the brushes inside the original alternator from my 91 Camry (4-cyl, auto, US assembled).

I checked the "rebuild your alternator" thread that Tercel GTS did...
Rebuild your own alternator
(awesome job by the way)

These were the warning lights that came on:


Here are pictures of the alternator after removal from the car:


Next, after I removed the 3 nuts and the cover:


Next I had to get the pulley off. I think you probably should use an impact wrench for this. I didn't have one, and I figured out another way to get it off with a regular socket, but it probably wasn't the best way to do it. Also, before I figured out how to get it off, I accidentally damaged the pulley slightly and created a rough edge on the belt contacting surface. I think it would have filed smooth enough not to be a problem.
Here is a picture of the pulley. It's kind of blurry, but if you look at the bottom, near 6 o'clock, you can see a light spot. This isn't flash-glare like on the rest of the picture. It is a little damage to the metal from trying to hold the pulley with pliers:

(btw…I was told that after re-assembly of the pulley, the threads should be sealed with a thread-locking compound.)

Next part is where I got stupid. I assumed my alternator disassembly would be identical to the one in Tercel's Post. Didn't realize that was on a Paseo. Instead of stopping to actually use my brain, I kept tapping...errr...banging..and BANGING...AND F@CKING BANGING...AND F@CKING BANGING THE MOTHERF@CKING, WHY THE F@CK WON"T YOU COME APART, MOTHERF@CKING rotor. By the time I realized my mistake it was too late.

There are 4 small screws that attach to the wires inside the alternator cover. You have to remove these 1st to get this type of alternator apart. (And presumably it would have come apart with a gentle tap...) Here I am pointing one of these 4 screws out:



After the alternator was taken apart:

You can see one of the terminals that the screws were going through at the bottom of the picture. It broke off.

Here is another view. You can see how the wires got stretched out and 2 of the terminals broke off:

[jefe]

At this point I coudln't figure out how to get the rotor out of the other half of the case, but since it was already damaged, I didn't try to figure it out. If you are only trying to replace the brushes, I don't think you would have to anyway.

Next I took off these screws I am pointing at with the screwdriver:


The next screws to remove were the ones holding the red/orange brush holder:

(You may notice the screws from the previous picture are still in. That is because I took all the pictures on reassembly.)

Here is the brush holder:

The actual brushes are the 2 small grey square parts. I don't exactly know how you would replace them. I know NAPA sold the replacement brushes for like $3. There are 2 in the package and they have a wire attached to one end. The other end needs to be soldered into the brush holder. There is also a spring to replace as they are spring loaded against the inside end of the rotor. The only thing I couldn't figure out is how to get the old ones out. It seemed like the brush holder was epoxied closed...

Here is the view after removal of the top part and brush holder:


I don't know if these are the "copper rings" or not...???

Here is some other damage to the internal parts. You can see the cracks on the lower left and lower right. I assume it cracked when I was banging it. Not sure if this can be fixed or not...


Here is the re-built one.

]

I am not too optimistic about getting another 222,000 miles out of it like I did on the original. Just swapping out the alternotor is really simple and would have taken about 15 minutes or less. Now I am trying to figure out what to do with the old core.

Thanks to everyone that helped me out, especially Tercel GTS, 95camguy, BullMarket, Pineapple, Whocares04, Neme5is, and Mike Gerber!!!

[MIGHTY]

120 dollars for an alt. man i paid 54.00 rebiult at kragen, try not to go to napa the have to pay nascar sponsors lol

[jefe]

Went to 5 places in town and it was the best price I got.

[McTimson]

My rebuilt one was like $90 after the core charges....

Thanks for the pics! Should be useful if I ever decide to try and fix an alternator myself.

[BullMarket]

Man...glad we could help out. Great contribution with all the pics...it helps us out to know what to expect and all. Take care bud and good motoring.

*edit...napa won't take your core?

BULLMKT

[Mike Gerber]

jefe,

Thanks for the pictures and your description. I will mark and save this just in case my alternator ever goes out. I'm surprised the brush kit didn't come with any instructions.

I was thinking of one thing when you wrote you scratched the front pulley trying to hold it to remove it. "That would be a nice place to try those strap wrenches I bought a few years ago and never used."

Anyway, thanks for the thank you.

Mike

[jefe]

NAPA would take the core. I have 30 days to return it. I just wanted to hang onto it till I heard from GTS. I figured since it was high quality OE it might be worth it to have IT rebuilt. GTS recommended hanging onto the old brush holder and turning the rest in since it had so much wear on the rotor and the part inside was cracked.

Also, NAPA had replacement brushes (2 in a little ziploc bag) for $3. The "Brush Replacement Kit" you can get (which probably includes instructions) was available at Auto-Zone for $30.

[BullMarket]

Originally Posted by jefe

NAPA would take the core. I have 30 days to return it. I just wanted to hang onto it till I heard from GTS. I figured since it was high quality OE it might be worth it to have IT rebuilt. GTS recommended hanging onto the old brush holder and turning the rest in since it had so much wear on the rotor and the part inside was cracked.

Also, NAPA had replacement brushes (2 in a little ziploc bag) for $3. The "Brush Replacement Kit" you can get (which probably includes instructions) was available at Auto-Zone for $30.

shoot him (GTS) a PM (private message)...threads can get lost sometimes

BULLMKT