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The objective of this repair guide is to instruct the reader how to remove and replace the stator in the CSC29 alternator. The stator is a series of copper windings that transfer current generated from the rapidly rotating rotor to the rectifier bridge assembly. This current eventually finds its way back into the car battery.
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Remove 4, 7.9mm nuts using a 7.9mm socket driver head
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Pull cover off the body of the alternator
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Once you have done this, you should be able to see the internal components of the alternator, particularly the bridge assembly that houses the rectifier, voltage regulator and brushes.
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With the alternator cover removed, use a #2 Phillips screwdriver to remove the two, 6 mm screws that hold the brush cover in place.
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Remove the brush cover assembly from the alternator. You might need to insert a needle in the small hole to separate the brushes from the rotor. Pull it out without using much force to avoid damage.
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Use a #2 Phillips screwdriver to remove the two 6mm screws holding down the voltage regulator
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Locate and unscrew the 3, 6mm screws holding the bridge assembly in place
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Locate the copper leads connecting the stator to the bridge assembly. There are 3 sets of 2 leads on the perimeter of the bridge, making 6 leads total.
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Use wire cutters to cut all 6 of the leads on the perimeter of the bridge.
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If necessary, use a pry bar to gently raise the top of the bridge assembly off the alternator
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Remove the lower section of the bridge assembly
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Use a Philips #2 Screwdriver or a 7.5mm socket driver to unscrew the 4, 7.5mm bolts running along the outer perimeter of the alternator
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Use a c-clamp or another fixture to hold the pulley in place
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Use a ratchet with a 25mm socket to remove the 25mm hex nut from the pulley
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Once the nut is off, you can then remove the pulley.
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Once the pulley is removed, separate the rotor and stator. The stator is the piece with copper windings.
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You can pull the stator out of the remaining cover and examine it.
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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Cal Poly, Team 25-1, Maness Spring 2016 crwdns2935289:0Cal Poly, Team 25-1, Maness Spring 2016crwdne2935289:0
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Thank you. Very good document, please keep up the excellent work.
