Contents: Bosch Generator ↳ Motorcraft Generator ↳ All types of generators ↳ Bosch Generator ↳ Motorcraft Generator ↳ All types of generators ↳
Note: You should already have the spare parts before beginning this procedure. At the time of writing, the alternator components were not available as spare parts. However, parts such as brushes can be purchased from auto electricians.
1. Remove the generator from the vehicle (paragraph 5) and place it on a clean workbench.
Bosch Generator
2. Remove the three screws and remove the plastic end cover (see Fig. 13.2).
3. Remove the two screws securing the voltage regulator/brush holder assembly.
4. Remove the regulator/brush holder from the end shield (see Fig. 6.4).
Motorcraft Generator
5. Remove the slotted head screws. Remove the regulator/brush holder from the rear of the generator (see Fig. 6.5).
All types of generators
6. Measure how much each brush protrudes and compare the resulting values with the minimum value specified in Technical requirements. If this parameter on one of the brushes is less than the specified value, replace the unit.
7. Make sure that each brush moves smoothly in the brush holder.
8. Make sure that the contact rings (the copper rings that support the brushes) are clean (see Fig. 6.8). Clean them with a rag soaked in solvent. If any of the rings are scored or blackened, the generator should be shown to a specialist.
Bosch Generator
9. Install the voltage regulator/brush holder so that the brushes are properly mated with the slip rings and are clamped in their support elements. Tighten the screws securely.
10. Install the end cover and tighten the screws securely.
Motorcraft Generator
11. Carefully press the brushes into the brush holder and secure them with a piece of wire through the hole (see Fig. 6.11).
12. Install the voltage regulator/brush holder. Tighten the screws securely (see Fig. 6.12).
All types of generators
13. Install the generator (paragraph 5).
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