(2) Using a small drill or a punch and hammer
remove epoxy which seals the three leads into the
housing.This must be done very carefully to avoid
damage to the housing. When all epoxy has been
removed from the hole, insert the new stator so that the
three leads protrude through the housing and reinstall
the fibre insulator around the leads. Replace the two
screws which secure the insulator. Reconnect the three
leads to the splices and solder them securely. Be sure
to slip the insulating sleeving over the splices when
completed. Place the stator and intermediate housing on
the bench with the stator facing upward and apply epoxy
around the stator leads. Sufficient epoxy should be used
to completely fill the recess in the housing around the
leads. Allow the epoxy to harden thoroughly before
reassembling the alternator.
i. Reassembly.
(1) Install new bearing on anti drive end of
rotor and press housing onto bearings. If the bearings
are to be replaced, special care must be used to avoid
damage. When pressing a bearing onto the shaft, apply
Figure 3-4. Diode markings
pressure to the inner face with a suitable tool. When
h. Stator Replacement.
pressing a bearing into a housing, press only on the
(1) When tests indicate an open or grounded
outer race. This will avoid applying force through the
stator, or if it is mechanically damaged, the stator must
bearing balls which will brinnell the bearing. When
be replaced. Unsolder the three stator leads from the
replacing seal, pack cavity 50 to 50% full of grease MIL-
splices and cut the three stator leads on both sides of the
G-3545B spec.
intermediate housing. These leads should be cut as
(2) Install rotor and housing assembly into
close to the housing as possible. The defective stator
stator and intermediate housing. When installing the
may now be removed from the intermediate housing by
rotor, it is necessary to use a fabricated tool to avoid
tapping it carefully with a soft hammer. Remove the two
damage to the seal. Details of the tool are shown in
screws which retain the insulator and carefully pry the
insulator off of the three leads.
Figure 3-5. Rotor installation tool.
(3) Insert the tapered end of the tool into the
(4) Insert the rotor into the stator and
intermediate housing seal from the drive end or brush
intermediate housing assembly so that the slip rings
holder site of the housing. Be sure that the surface of
enter the recess in the end of the tool.
the tool which enters the seal is free from nicks and
Carefully slide the rotor into the stator and housing
burrs which would damage the seal.
assembly. The tool will be forced back out of the seal as
the rotor shaft enters. The
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