Alternator & Regulator: Overhaul: Sidekick: Disassembly
- Scribe mark on front and rear housing for reassembly reference. Remove housing bolts. Using a 200-watt soldering iron, heat rear bearing to 120-140° F (50-60° C). Insert lever between stator core and front housing and separate alternator halves.
- Mount alternator rotor in a soft-jawed vise. Remove pulley nut and pulley. Remove rotor from front housing. See Figure. Remove 4 retaining screws, front bearing retainer plate and front bearing from front housing (if required).
- If rear bearing requires replacement, mount rotor in bearing separator plate and remove bearing using a hydraulic press. Remove 4 stator retaining screws, battery terminal nut and stator from alternator rear housing. If brushes require replacement, remove wire cover from brush holder and remove brush wires from regulator using a soldering iron.