TM 5-3805-260-24
DISASSEMBLE DELCO REMY ALTERNATOR
1. Position alternator in a vise or similar clamping
device.
CAUTION
Be careful not to over tighten alternator in vise.
Damage is possible to alternator if vise is
overtightened.
2. Retain alternator pulley (1) and remove lock-nut
(2) and washer (3). Remove alternator pulley.
NOTE: Refer to page 3-10A for illustration. 3.
Remove fan (4).
4. Remove four bolts (5) and pull end frame (6) and
rotor (7) out of the alternator housing as an
assembly.
5. Press rotor (7) out of end frame (6).
6 Remove three screws (8), retainer (9), and collar
(10).
7. Remove shield (I 1) and collar (12).
8. Press bearing (13) out of end frame (6).
9.
Remove plate (14) and washer (15).
10. Remove four screws (16) and regulator
cover (17).
11. Disconnect three stator leads that are attached to
regulator (18) by removing nuts (19) from rectifier
bridge (20).
12. Remove nut securing regulator connector ( 1) to
regulator.
13. Remove nut (22) and field coil lead from regulator
(18).
14. Remove screw (23) and remaining field coil lead
from regulator (18).
15. Remove two regulator mounting screws (24), lock
washers (25), washers (26), and regulator (18).
16. Remove nut (27), lock washer (’8), and washer (29)
from
alternator
output
terminal.
17Remove nut (30) and insulator (31) from output
terminal.
18. Remove screw (32), washer (33), bushing (34),
connector (35), and output terminal (36) with
terminal insulator (37).
19. Remove cap (38).
20. Remove nut which secures connector (39) to
regulator (20).
21. Remove nut (40) and connector (39).
22. Remove nut (41), insulators (42, 43, 44). And
relay terminal (45).
23. Remove screw (46), washer (47), and connector
(2 1).
24. Remove rectifier bridge mounting screws (-18) and
remove rectifier bridge (20) and bridge insulator
(49).
25. Remove screw (50), suppression capacitor (51),
and capacitor bracket (52).
26. If necessary, remove diodes (53) from rectifier
bridge (20).
27. Remove screws (54) and field coil/support
assembly (55).
28. Pull stator (56) leads and grommet (57) from stator
housing (58). Remove stator.
29. If necessary, remove bearing (59) from stator
housing.
30. If necessary, remove hinge bushing (60)
ASSEMBLE DELCO REMY ALTERNATOR
1. If removed, press hinge bushing (60) into stator
housing (58).
2. Use Delco-Remy lubricant (Part No. 1948791) to fill
reservoir on bearing (57) half full. Posi-tion
lubricant so that a portion of the lubricant touches
the bearing surface.
3. Press bearing (59) into stator housing until end of
bearing is even with the inside of the stator
housing.
3-9
