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How to: 4g alternator rebuild with pictures

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donalds

Elite Explorer
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Stem
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Year, Model & Trim Level
1999 ford explorer sohc
So about a year ago I bought a remanufactured alternator
From autocrap
Since then the bearings went out twice making lots of noise
So instead of changing it again for warranty I figured I may as well rebuild it the correct way and make a how to thread
 



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Remove the alternator from the truck

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Remove pulley and the 3 bolts
Then the cover

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Mark the case for easy assembly
Remove voltage regulator I marked the screws in yellow
I put mine on a couple blocks of wood
Then hold the back of the alternator and tap the ears lightly to remove the drive end housing
Flip over the stator assembly and place it on two pieces of wood only on the stator plates not the coil windings ..important.. then tap out your bearing and rotor assembly
They will fall out together

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Remove bearing retainer
Tap out bearing

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Let's compare the voltage regulator s
One is a new heavy duty
The old one was rebuilt

Look at the brush holder area you can see where the rebuilt motor craft regulator was drilled then soldered new brushes in then glue to cover it up

The new one is just that new

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Install your new bearing into the drive end housing replace retainer

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Place drive end housing on two blocks of wood and insert new rotor slip ring assembly in to the housing

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Clean your ground path and voltage regulator mounting points
I put yellow arrows for help

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Line up your marks and install the stator assembly it will basically fall in if you did a good job cleaning your ground path I used the bolts loosely threaded in as a guide pins don't use the bolts to pull in the stator

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Tap in your new bearing
Install your new voltage regulator put some dielectric grease on the mounting points

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Install cover with the three main housing bolts
Don't strip the therads

Install pulley with a impact wrench

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And it will outlast every rebuild you could ever buy off the shelf. I swore off rebuilding alternators myself after I did a rebuild on my sisters beretta, and had to de-solder the rectifier before i could even split it. With no soldering this is a breeze. I should have rebuilt my own spring before last, and I probably wouldn't have had to take the replacement rebuild in for a warranty replacement rebuild 6 months later. Well done. Any recommendations for rebuild kits?
 






And it will outlast every rebuild you could ever buy off the shelf. I swore off rebuilding alternators myself after I did a rebuild on my sisters beretta, and had to de-solder the rectifier before i could even split it. With no soldering this is a breeze. I should have rebuilt my own spring before last, and I probably wouldn't have had to take the replacement rebuild in for a warranty replacement rebuild 6 months later. Well done. Any recommendations for rebuild kits?
Alternator Starter Rebuild Kits

I also rebuilt my starter with their kit as well that was 4 years ago
 






Quite a DIY Donald. Great thread and I'm sure it will be useful to many. I'm printing and saving this NOW. Thanks!
 









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