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  1. #1
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default [How-To] Disassemble the Alternator & Polish

    This is described in the BGB, but it does call for some SST's which aren't totally necessary, so I'll show you how I did it.

    This is an alternator from a 1990 3S-GTE.

    Here is the BGB's breakdown of parts:



    A very visible piece on our motors is the alternator, and usually due to corrosion, they look very well weathered after a few years on the road. Here's mine (ewwe!)



    The first and possibly most challenging piece to remove is the pulley. Many people can use an impact gun on the 22mm nut and hold the pulley by hand and it will pop off. I used a vice to secure the pulley and a big breaker bar. Just be careful not to damage your pulley.





    On the other side there are 4 nuts holding the two housing halves together. Remove these but be careful not to strip them.



    Now remove the end cover. Remove all of the nuts, the electrical plug, and the wire.



    The cover will come right off.



    Next remove the 5 screws securing the brushes & holder and IC regulator.



    Now remove the 4 screws on the side holding on the rectifier holder. Remove the rubber grommets that go over the wires as well.



    Rectifier holder removed



    From here, you should be able to separate the two housing halves. You should have this:



    Now remove the rotor. To do so you will need a puller device as it is press fit in place.



    Here is the housing with the rotor removed.



    And here is everything together:



    I have not yet found a way to remove the stator / coil from the casing.

    To be continued.
    1988 ST165 2.2L @ 370awhp
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  2. #2
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    Starting Point:



    After ~1 hour sanding with 80 grit, and with sanding attachment on electric drill as shown in pics:

    No Flash



    With Flash

    Last edited by ChrisD; 01-19-2011 at 11:34 PM.
    1988 ST165 2.2L @ 370awhp
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  3. #3

    Default

    excellent work Chris. That brush set can be purchased from toyota for around $18 or you can get a set of solder in place replacement brushes for about $5 from any auto parts store. I got mine from Napa. You simply unsolder the point at the back of the holder, remove old brush, replace with new brush pulling the brush far enough into the holder to keep it from flopping over, then solder the braided copper wire into place.

    (Chris, if you go with a toyota set, for the "how to" it might be nice to show the process anyway.)
    “It's amazing how once the mind is free of emotional pollution, logic and clarity emerge...
    Yet, it's our emotions and imperfections that makes us human.”
    ― Clyde DeSouza,

  4. #4
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    ^Good tips, thanks.

    Not sure which I'll go with quite yet, but will definitely outline the process with pics as well.
    1988 ST165 2.2L @ 370awhp
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  5. #5

    Default

    looks to me like your brushes were at the end of their life anway.
    “It's amazing how once the mind is free of emotional pollution, logic and clarity emerge...
    Yet, it's our emotions and imperfections that makes us human.”
    ― Clyde DeSouza,

  6. #6
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    Probably. I'll measure them for kicks anyway, but they've got ~110,000 km's on them.
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  7. #7
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Updated post 2 with polishing progress so far. 1 hour spent, probably will take at least 5-6 hours I'm thinking.
    1988 ST165 2.2L @ 370awhp
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  8. #8

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    You da man.

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    Originally Posted by Murgatroy
    I was deaf, sore and majorly pissed off

  9. #9
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    Bumping this so I can find it again. Update coming.
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  10. #10
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    Removing the stator basically involved slowly tapping it out with a driver and hammer through the slots.

    Click image for larger version

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    Decided not to do the polishing and had it ceramic coated. Pics coming soon!
    1988 ST165 2.2L @ 370awhp
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  11. #11

    Default

    Took you 2 1/2 years to tap that fucker out?!!!!! That's patience.

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  12. #12
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    LOL!

    Ya, I had a baby, things got put on hold. Did some projects on the 205 in the mean time.
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  13. #13
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Some reassembly pics... Had the casing ceramic coated, love how it turned out.

    Reinstall the bearing.

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    Tap the stator back in. (don't put the rubber spacers back in until the casing is together again, I was just test fitting various things)

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    Pop the rotor back in.

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    FIRST, install the long studs with the nut in them half way down. Then, got the two halves together and then eh the 4 nuts.

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    Now put those rubber grommets in.

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  14. #14
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Pop on the rectifier.

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    Attach the wires with screws.

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    Install new brushes while you're at it! Mine have 100,000kms on then to give you an idea of wear.

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    Fitted along with the IC regulator by 5 screws. Don't forget the rubber spacer underneath.

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    Rubber cap on top.

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  15. #15
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Pop on the last cover with the wire, connector, and studs / nuts.

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    Admire your work!

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    And one to give an idea of what it will look like in the engine bay.

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  16. #16

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    I really like how it turned out Chris.
    - Mario
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    Questions?

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    "We are what we repeatedly do. Excellence, then, is not an act, but a Habit."

  17. #17
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Default

    Thanks Mario! Me too!

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  18. #18

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    Looks really good man.

    The first thing I saw when I looked at the installed pic was the header. lol.

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    - sold
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  19. #19
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    Default

    Shiney!!!

    Quote Originally Posted by crymson View Post
    Looks really good man.

    The first thing I saw when I looked at the installed pic was the header. lol.
    Me too.

    Are you going to ceramic coat the manifold/adapter/turbine housing too?
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    I told him that he shouldn't be ashamed of being gay. He should be ashamed of stealing that ladies dick.

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  20. #20
    Ultimo Miembro Fantástico Gigantesco ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD has much to be proud of ChrisD's Avatar
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    Lol. Everything is still a work in progress so it's not the final view yet. (even still, it's all a product of time and money and I'm limited in both!). Not to mention I will polish the Ic piping and have a shiny bov going on.

    I do have a shiny heat shield I'll be installing that will cover the manifold. Turbo is already coated.

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  21. #21
    Resident Japexican Ninjaneer
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    I just noticed that you're ST165-0004333....

    Stacy's is 4982 lol

    Would've been cooler if they were closer, but 649 units in a 10000 unit run isn't bad
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    I told him that he shouldn't be ashamed of being gay. He should be ashamed of stealing that ladies dick.

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  22. #22

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    Chris, did you replace brushes and other parts?

    Facime, if you have rebuilt one of these things, maybe a writeup would be cool?

    I have an alternator that needs to be rebuilt. Id send it to you and pay for all the stuff if you wanted to do it and do a writeup. Id even pay you a bit.

    Unless the writeup is already there then Ill just follow it.
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    Originally Posted by surfergravity
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    This thread is gayer than Richard Simmons singing a duet with Elton John in a bath house.

  23. #23

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    uhhhhh....everything you need to know about rebuilding one is right here in this tread. Did you even read the thread man!?
    “It's amazing how once the mind is free of emotional pollution, logic and clarity emerge...
    Yet, it's our emotions and imperfections that makes us human.”
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  24. #24

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    What?

    He didnt put part numbers, or where shit is located, where he got it from, etc.
    2000 Absolute Red Celica GTS 6-Spd
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    Originally Posted by surfergravity
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    This thread is gayer than Richard Simmons singing a duet with Elton John in a bath house.

  25. #25

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    geez! do you need me to hold your hand while you do it as well?

    “It's amazing how once the mind is free of emotional pollution, logic and clarity emerge...
    Yet, it's our emotions and imperfections that makes us human.”
    ― Clyde DeSouza,

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