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2nd Gen 1GRFE Alternator Rebuild - Mud cleanout

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Sandman614, Oct 1, 2016.

  1. Oct 1, 2016 at 8:22 PM
    #1
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    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
    IMG_20160926_192558.jpg

    Bad diode:
    IMG_20161001_155331.jpg

    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/
    IMG_20161001_102300.jpg

    Step 3: Remove rear cover, 3x8mm nuts.
    IMG_20161001_155226.jpg

    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.
    IMG_20161001_220140.jpg

    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.
    IMG_20161001_155650.jpg

    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.
    IMG_20161001_164737.jpg

    Step 7: Remove the plug from the old diode assembly. I used the dremel again.
    IMG_20161001_195414.jpg
    IMG_20161001_211712.jpg

    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
    IMG_20161001_164922.jpg
    IMG_20161001_165244.jpg
    IMG_20161001_220355.jpg

    Step 10: Reinstall brushes
    IMG_20161001_220241.jpg

    Step 11: Reinstall rear cover

    Step 12: Take alternator to Auto Parts store and have it bench tested.
     
    Last edited: May 3, 2017
  2. Oct 1, 2016 at 8:39 PM
    #2
    Dragons Taco

    Dragons Taco Well-Known Member

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    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)
     
    seniorredwood likes this.
  3. Oct 1, 2016 at 8:42 PM
    #3
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    Haha yea so Step 5.5: clean the mud out of the Brushes and reinstall lol.
     
    seniorredwood likes this.
  4. Oct 1, 2016 at 8:52 PM
    #4
    DukesTaco

    DukesTaco Well-Known Member

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    Nice write-up. Subbing for future rebuild.
     
    Sandman614 [OP] likes this.
  5. Oct 2, 2016 at 5:54 AM
    #5
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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  6. Oct 2, 2016 at 8:32 AM
    #6
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    Autozone says it passed. Topping off my battery with my charger now.
     
    Manfred and seniorredwood like this.
  7. Oct 2, 2016 at 12:56 PM
    #7
    Tex-Tac

    Tex-Tac Well-Known Member

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    Installed Overhead Compass and Temperature Display along with outside temperature sensor and wiring; LED lights reverse backup; LED license plate lights; Added GTA Bluetooth Audio kit to stock radio for iphone audio; Spare tire steel braided air hose extension connection to rear bumper; Installed new headlights along with new bulbs PIAA H4 XTreme and for fog lights PIAA H10 XTreme bulbs. Installed new hood with "hood-scoop". Installed Predator Side Steps. Replaced front chrome grill with customized color matched (Desert Sand Mica) grill with added TOYOTA lettering (also in matched color), installed and secured tailgate anti-theft devices. Also installed a new external TPMS monitor for all 4 tires.
    Sub'd
     
    seniorredwood likes this.
  8. Feb 25, 2017 at 4:03 PM
    #8
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    Update: All is well
     
    Manfred and seniorredwood like this.
  9. Mar 13, 2017 at 9:23 PM
    #9
    T4RFTMFW

    T4RFTMFW #DBBeer

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  10. Jun 29, 2017 at 1:52 PM
    #10
    ItalynStylion

    ItalynStylion Sounds Gooooood

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    Great thread! That video of the alternator in the camry whining sounds JUST like mine. Pretty sure I have my marching orders.
     
    Sandman614 [OP] likes this.
  11. Oct 19, 2018 at 10:08 AM
    #11
    swede31188

    swede31188 Well-Known Member

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  12. Apr 9, 2019 at 9:49 AM
    #12
    Manfred

    Manfred Well-Known Member

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    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.
     
  13. Apr 9, 2019 at 10:56 AM
    #13
    burntkat

    burntkat Well-Known Member

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    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.
     
  14. Apr 9, 2019 at 10:58 AM
    #14
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    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
     
    PzTank and burntkat like this.
  15. Apr 9, 2019 at 11:19 AM
    #15
    burntkat

    burntkat Well-Known Member

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    Absolutely, in event of a rebuild, it is worth the time. But it's kind of hard to screw up bolting parts in. ;)
     
  16. Apr 9, 2019 at 1:13 PM
    #16
    PzTank

    PzTank ☕️

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    How’s it holding out after 2 1/2 years post rebuild?
     
  17. Apr 9, 2019 at 1:13 PM
    #17
    Sandman614

    Sandman614 [OP] Snarky TWSS elf, Travis #hotsavannahdotcom, LRGRNR

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    Stilll going good!
     

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