Alternator, Disassemble
Remove alternator - see operation "Alternator, Remove and Install" in this group.
Unbolt vacuum pump from alternator.
Note seal ring.
Loosen retaining spring (arrow) and disconnect wiring harness plug.
Loosen bolts (1) fastening cables.
Remove rubber cap (1) and loosen nut underneath.
Remove wiring harness.
Note installation position of insulating sleeve.
Mark position of front and rear housing covers to stator.
Unscrew through bolts (2).
Carefully lever off front housing cover from stator using screwdriver and remove rear housing cover assembly upwards (see illus. III).
Unbolt nuts (3) from rear housing cover.
Carefully lever off stator from rear housing cover and remove from housing with diode plate, regulator and carbon brushes (see illus. I).
Tension Allen wrench in vice to counterhold.
Unbolt pulley nut from armature shaft (see illus. II).
Remove pulley split washer, fan, spacer ring and front housing cover from armature shaft (see illus. III).
Tension armature shaft in vice - use protective jaws.
Remove ball bearing on slip ring side using commercially available bearing puller (see illus. IV).
Unbolt bearing retainer ring from front housing cover (arrows).
Press ball bearing out of front housing cover by hand.
If necessary, carefully drive out with suitable mounting sleeve and hammer.
Press simmer ring out of rear housing cover with screwdriver or other suitable tool.
Bend diode plate up carefully from stator.
Unsolder phase guides (arrows) of stator windings.
To avoid overheating the diodes during soldering, hold connecting cable with flat pliers - this conducts the heat away. Solder as fast as possible.
To remove the carbon brush holder, remove insulating sleeve (1) - observe installation position - and unsolder connection between carbon brush holder and diode plate (arrow).
Remove carbon brush holder.