2nd Gen 1GRFE Alternator Rebuild - Mud cleanout

https://youtu.be/J0CyhCAW9fc

So after much, much, much, searching there isn't much info on this topic for 2005-2016 Tacomas. There is however a good amount of info for 1st gens.. My truck started making a whining sound, not coming through the speakers. After some deliberation and confirmation from this Youtube video I decided to rebuild my alternator.
https://youtu.be/hmPUUVwIJUU

Stock 100 amp non-towing Denso:
Toyota 27060-0P030
Denso TN104210-4230


Bad diode:


Part: ALTERNATOR HD DIODE RECTIFIER http://www.ebay.com/itm/291236997680

Step 1: Disconnect alternator from battery. I disconnected at the alternator connection in the fuse box.

Step 2: Remove your alternator, 1 battery cable, 1 connectors, 2x14mm mounting bolts and 2x10mm wire loom bolts. Probably have to remove serpentine belt.
https://www.tacomaworld.com/threads/how-to-change-the-alternator-on-a-2nd-gen-tacoma.175116/


Step 3: Remove rear cover, 3x8mm nuts.


Step 4: Remove brush housing, 2 phillips screws. Inspect and/or replace brushes. Stick a paperclip, needle, toothpic, etc through like this so you don't loose the brushes.


Step 4.5: clean the mud out of the Brushes and reinstall
Skip to step 10 if you are here for mud cleanout

Step 5: Remove diode assembly, phillips screws marked here in blue.


Step 6: Disconnect the 3 sets of winding wires coming up through diode assembly. I used a dremel and carfully cut the 'welds'. Take care not to cut the wires short or thin.


Step 7: Remove the plug from the old diode assembly. I used the dremel again.



Step 8: Remove old diode Assembly

Step 9: Install new diode Assembly and reconnect the 3 sets of winding wires. I soldered them on after seeing this video.
https://youtu.be/ZupcMqBYeew




Step 10: Reinstall brushes


Step 11: Reinstall rear cover

Step 12: Take alternator to Auto Parts store and have it bench tested.

 

Great tutorial! Nice job with the pics! I know u wanted to do a thread on this as a trail fix, (cleaning mud from the brushes) but your rebuild details are also worth having if peeps can find a regulator.

Caution to folks with a tow package. The regulator listed here may not be able to support the current available in the higher capacity alternator and be shorter lived if under a big load. (Dead battery for instance)

 

Haha yea so Step 5.5: clean the mud out of the Brushes and reinstall lol.

 

Nice write-up. Subbing for future rebuild.

 

Here's a removal thread that popped up.
https://www.tacomaworld.com/threads/how-to-change-the-alternator-on-a-2nd-gen-tacoma.175116/

 

Autozone says it passed. Topping off my battery with my charger now.

 

Sub'd

 

Update: All is well

 

@b.prall

 

Great thread! That video of the alternator in the camry whining sounds JUST like mine. Pretty sure I have my marching orders.

 

Thanks

 

I think you may have helped me diagnose the whinning sound coming from the drivers side of the engine bay but ill have to confirm with a screw driver. It started last july after going through a deep puddle SO its on my list of suspects.

 

Fyi, these parts store testers are a wild ass guess backed up with numbers. You want to test the item hot and in situ if at all possible, not on a bench.

 

Better to have a guess with numbers than tear it back out again if you messed up or the new part is bad. But you do you

 

Absolutely, in event of a rebuild, it is worth the time. But it's kind of hard to screw up bolting parts in.

 

How’s it holding out after 2 1/2 years post rebuild?

 

Stilll going good!

 

Hey @Sandman614, can you inspect the diode while on the truck / is it always the diode? I have the exact same noise that started this morning. Considering rebuild vs replace.

 

If you were a midget that might be possible. I'd say it's likely to probably it. I don't know another reason the alternator would make a noise like that.

 

Cool. I understand what the pictures are of now. 173k on the truck now. I'll order the 130A version of the rectifier