1980 through 1987 models have an integral voltage regulator mounted on the side of the alternator body, accessible with the alternator in the vehicle. 1988 through 1992 models have a true internal regulator attached to the rectifier assembly within the alternator body. 1993 and later models have an integral voltage regulator and brush assembly accessible by removing the rear cover from the back of the alternator. The alternator must be removed from the vehicle first. This procedure covers only the 1993 and later models. The alternators are basically the same but differ in voltage regulator designs. To disassemble, remove the alternator and place it on a clean workbench. Remove the rear cover nuts, nut and terminal insulator, and the rear cover. Remove the five voltage regulator and brush holder mounting screws. Remove the brush holder and regulator from the rear end frame. If only replacing the regulator, proceed to install the new unit, reassemble the alternator, and install it on the engine. If replacing the brushes, measure the exposed length of each brush and compare it to the minimum length. If necessary, replace the brushes and brush holder assembly. Make sure each brush moves smoothly in the brush holder. Remove the rectifier assembly by removing the mounting screws, rubber insulators, and seal plate. Scribe or paint marks on the front and rear end frame housings for reassembly. Remove the nut retaining the pulley to the rotor shaft and remove the pulley. Remove the four nuts retaining the front and rear end frames together, then separate the rear end frame assembly from the front end frame. Remove the thrust washer and remove the rotor from the front end frame. For component checks, check for an open between the two slip rings and for grounds between each slip ring and the rotor. Check for opens between each end terminal of the stator windings and for a grounded stator winding between each stator terminal and the frame. Check the positive and negative rectifiers by checking continuity and polarity. If any components fail the tests, they are defective. To reassemble, install the components in the reverse order of removal, ensuring the brush holder is depressed to clear the shaft. Tighten all nuts and screws securely. Finally, install the alternator.
