Charging System (Service Information): Generator: Disassembly: Disassembly

REMOVE CLUTCH PULLEY
1. Using a screwdriver, remove the generator pulley cap.
  
  Fig 1: Identifying Generator Pulley Cap
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Set SST (A) and (B).
  
  Fig 2: Setting SST (A) & (B)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09820-63020
3. Clamp SST (A) in a vise.
4. Place the rotor shaft end into SST (A).
  
  Fig 3: Placing Rotor Shaft End Into SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Fit SST (B) to the clutch pulley.
  
  Fig 4: Fitting SST To Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. Loosen the pulley by turning SST (B) in the direction shown in the illustration.
  
  Fig 5: Loosening Pulley By Turning SST
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. Remove the generator assembly from the SST.
8. Remove the clutch pulley from the rotor shaft.
REMOVE GENERATOR REAR END COVER
1. Place the generator assembly on the clutch pulley.
  
  Fig 6: Identifying Generator Assembly & Clutch Pulley
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the 3 nuts and end cover.
  
  Fig 7: Identifying Clutch Pulley & Rotor Shaft
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE TERMINAL INSULATOR
1. Remove the terminal insulator from the generator coil.
  
  Fig 8: Identifying Terminal Insulator
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR BRUSH HOLDER ASSEMBLY
1. Remove the 2 screws and brush holder from the generator coil.
  
  Fig 9: Identifying Screws & Brush Holder
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
REMOVE GENERATOR COIL ASSEMBLY
1. Remove the 4 bolts.
  
  Fig 10: Identifying Generator Coil Assembly Bolts
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST, remove the generator coil assembly.
  
  Fig 11: Using SST To Remove Generator Coil Assembly
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-40011
    - 09951-04020
    - 09952-04010
    - 09953-04020
    - 09954-04010
    - 09955-04071
    - 09957-04010
    - 09958-04011
REMOVE GENERATOR ROTOR ASSEMBLY
1. Remove the generator washer.
  
  Fig 12: Identifying Generator Washer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Remove the rotor assembly from the drive end frame.
  
  Fig 13: Identifying Rotor Assembly To Drive End Frame
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT GENERATOR DRIVE END FRAME BEARING See step 4
REMOVE GENERATOR DRIVE END FRAME BEARING
1. Remove the 4 screws and retainer plate from the drive end frame.
  
  Fig 14: Identifying Retainer Plate & Drive End Frame Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using SST and a hammer, tap out the drive end frame bearing from the drive end frame.
  
  Fig 15: Tapping Out Drive End Frame Bearing From Drive End Frame Using SST & Hammer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  - SST: 09950-60010
    - 09951-00250
  - SST: 09950-70010
    - 09951-07100