04-02-2019, 02:01 PM
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#1
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Rebuild Alternator (W/ Pics)
So I've been doing a bunch of work on my car and one of the things that I've been curious about is the condition of my alternator. It has been working well but with my commute I don't want to break down. The alternator is Toyota Denso so I am assuming it is original to the car and from seeing the lack of maintenance from the previous owner, I also assumed it had never been rebuilt. So I ordered a bunch of parts and decided to attempt to rebuild it myself, including the bearings.
Parts;
27370-75060 BRUSH & HOLDER ASSY, ALTERNA
27388-42010 BRUSH, COVER
27443-63020 COVER, BEARING
90099-10140 BEARING
90099-10192 BEARING
27064-42010 SEAL SUB-ASSY, PLATE
27384-50030 WASHER, ALTERNATOR
27387-42021 INSULATION, WASHER T
27389-42010 INSULATOR, TERMINAL (NEED 4)
First, Remove the alternator. Fairly straight forward.
Remove both both nuts from the alternator post. Then the plastic insulator underneath can be easily removed.
Remove the three 10mm nuts and the phillips screw holding down the alternator shield. Be careful not to lose the small metal tab that goes between one of the the nuts and the phillips screw. The metal shield can now be removed.
Remove the five phillips screws that were under the shield. You can then remove the brush assembly and the regulator. Yup, the brushes are looking pretty worn out. Unscrew the four phillips screws holding the alternator post assembly. Remove the four rubber insulators.
You'll need to remove the alternator pulley nut. I used an impact to break it loose since I didn't think about this until after it was out of the vehicle. Remove the alternator pulley. Remove the 4 (8mm or 10mm) nuts holding the outer shell together. Then you'll need to gradually work the two pieces apart. I used a hammer and screwdriver to tap them apart enough to get a flat head screwdriver on opposite sides and pry it apart the rest of the way. Be careful with the four copper wire ends that stick up as you work on the rest. Now to work on the two halves.
Last edited by Novashards; 04-02-2019 at 03:23 PM.
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04-02-2019, 02:02 PM
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#2
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Last edited by Novashards; 04-02-2019 at 02:34 PM.
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04-02-2019, 02:02 PM
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#3
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Last edited by Novashards; 04-02-2019 at 02:54 PM.
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04-02-2019, 02:55 PM
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#4
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fantastic post.. very well documented.. thanks for taking the effort and time to take such clear shots..
is there any way of replacing the copper sections on the shaft? they seem to be a bit worn down.
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04-02-2019, 02:58 PM
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#5
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Quote:
Originally Posted by Jungoes
fantastic post.. very well documented.. thanks for taking the effort and time to take such clear shots..
is there any way of replacing the copper sections on the shaft? they seem to be a bit worn down.
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I noticed it was worn but I didn't see any replacement part listed separate from buying the whole rotor assembly, and that was a little too expensive. I also am not sure if or how it would be removed.
2000 Toyota 4Runner Alternator Parts
Last edited by Novashards; 04-02-2019 at 03:01 PM.
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04-02-2019, 06:56 PM
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#6
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Join Date: Jul 2016
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Real Name: Alex
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This is fantastic. Usually an alternator is just thought of as a full replacement item. But I like this better. Great pictures and write up.
Do you think you saved enough money on it to justify the time (regardless of the fun in doing this)?
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04-02-2019, 07:19 PM
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#7
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I found this thread showing someone removing the slip ring. It looks fairly simple to remove except I'm not sure where the wires go and how easy it would be to solder them.
Post #22
Alternator bearing replacement?
I believe this is the slip ring. I just ordered the one from amazon and will be replacing it since mine has a deep groove in it. I really wish I had known about this part ahead of time so I could have replaced it at the same time. Taking apart the alternator isn't hard, but pulling the smaller bearing off is a little bit of a pain.
Slip Ring: 8.8mm ID x 14.5mm OD
SLIP RING, ROTOR - 28-82853
Nippondenso internal fan alternator slip ring for Chrysler, Honda, Suzuki, Toyota - 7190904
Last edited by Novashards; 04-02-2019 at 07:57 PM.
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04-02-2019, 07:25 PM
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#8
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Quote:
Originally Posted by raKnizek
This is fantastic. Usually an alternator is just thought of as a full replacement item. But I like this better. Great pictures and write up.
Do you think you saved enough money on it to justify the time (regardless of the fun in doing this)?
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I enjoyed the puzzle of rebuilding it and prefer to keep OEM quality for most things, especially when I can offset costs by repairing it myself.
All of the parts I ordered were $85.
I probably could have just reused a bunch of the smaller parts so if you just count the cost of the two bearings and a brush assembly it would have been $52.
I didn't really shop around much so you might be able to find them cheaper.
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01-13-2020, 06:59 PM
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#9
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Awesome post! Great pics also
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01-29-2021, 02:15 PM
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#10
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thanks for this post.
ws trying to find one that went into more than just brushes. Watched timmys for brush replacement on my last 4runner.
My current 4runner alt has 280k on it, looks original anyway, it is a denso and has the denso sticker but does not say rebuilt.
Anyway, wanted to do more than just brushes, wont get to it for a month or so, but anyway, thanks for this post and clear directions
anyone running one wiht more miles with original bearings ?
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01-29-2021, 03:12 PM
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#11
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Fantastic write-up! Thanks for the effort and solid photos.
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02-12-2023, 12:49 PM
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#12
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Reviving a thread from the dead
I had a Denso alt go bad, so I sourced a junkyard unit out of another 4runner, it eventually died, too. Pulled it apart and found the brush holder was different than what OP posted
Attachment 402861
As expected, the brushes were gone, here is what new ones look like (spring loaded to contact the shaft)
Turns out there are potentially 2 different brush holders for these trucks/alternators, and without the VIN both will be "correct" for our trucks on parts.toyota.com
OP posted 27370-75060 which is the correct brush holder for an 80 amp Alternator
27370-35060 is for the 60 amp, and fits a 10+ vehicles
The tag on my bad alt was worn, so I bought both brush holders before cracking mine open, low and behold, I had the smaller 60 amp alternator.
The brush holder swap was as simple as removing 4 nuts and 2 screws.
Done and back on the road - I did not want to mess with the bearings lol
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Last edited by octanejunkie; 02-12-2023 at 01:00 PM.
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02-12-2023, 01:29 PM
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#13
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Join Date: Feb 2015
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I think this is an awesome write-up and I definitely support the DIY approach. But, some jobs just look like too much of a hassle for the savings, this being one of those jobs. Same goes for rebuilding a steering rack. Once you quantify how much you spent on the rebuild kit and your time, the replacement one from Toyota looks pretty attractive.
I definitely support the easy and affordable fix of replacing brushes. An involved rebuild like this to save maybe $100, I'm not so sure it's worth it. You can purchase rebuilt Denso alternators for a pretty affordable cost. My two cents.
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02-12-2023, 01:47 PM
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#14
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Quote:
Originally Posted by octanejunkie
Reviving a thread from the dead
I had a Denso alt go bad, so I sourced a junkyard unit out of another 4runner, it eventually died, too. Pulled it apart and found the brush holder was different than what OP posted
Attachment 402861
As expected, the brushes were gone, here is what new ones look like (spring loaded to contact the shaft)
Turns out there are potentially 2 different brush holders for these trucks/alternators, and without the VIN both will be "correct" for our trucks on parts.toyota.com
OP posted 27370-75060 which is the correct brush holder for an 80 amp Alternator
27370-35060 is for the 60 amp, and fits a 10+ vehicles
The tag on my bad alt was worn, so I bought both brush holders before cracking mine open, low and behold, I had the smaller 60 amp alternator.
The brush holder swap was as simple as removing 4 nuts and 2 screws.
Done and back on the road - I did not want to mess with the bearings lol
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I discovered that also when I rebuilt my smaller Alt and then discovered the 80a has different brushes. They are only 20 ish dollars (or were 4-5 years ago) at the dealer…..easy repair.
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02-12-2023, 02:13 PM
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#15
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Quote:
Originally Posted by mtbtim
... I definitely support the DIY approach. But, some jobs just look like too much of a hassle for the savings, this being one of those jobs. ... I'm not so sure it's worth it. You can purchase rebuilt Denso alternators for a pretty affordable cost...
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That's what my retired buddy NYC mechanic said, "I've never rebuilt an alternator, steering rack or brake caliper and don't know how", for that exact reason, I was floored.
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