had a few question on this too so i though id post to all, they way you keep the brushes back in to put the shaft back in is by using the small hole in the back of the alternator shell, use a paperclip or coat-hanger and slide it in the hole, then push the brushes in, they need to go very deep in, and you can slide the rod farther up and it will hold the brushes back, then put the alternator center back in, and pull our the rod that held the brushes back, here are some pics:





by the way, i used a tool that came with my cdrom drive to get cds out when the drive is off, its just a metal rod with a plastic handle

 

Damian...you are the man, thanks for answering this for me. Love the pics man, i understand perfectly now
Thanks again

Jack

 

no problemo :-)

 

Hey While on sorta the subject.. I'm thinking about removing my alternator and painting it. Is this (the brushes ) the biggest thing I have to deal with? Anything to watch for?

 

the biggest hassle is gettin the main bolt off, you need an impact wrench becasue the pulley will just spin if you try to do it with a wrench, other than that, just be carefull with the internal parts, there is not many so its not a complex deal

 

damian=my hero...I can finish my car now yay!!!

 

When I was rebuilding my alternator, I noticed the hole in back and the little rubber seal. After looking at it a little more, I realized what it was for before I even realized that it's almost impossible to reassemble the alternator without it.

I thought it was so cool, I even looked in the shop manual for it. And guess what? No mention.

I also got the pulley bolt off with hand tools. I used an old alternator belt, a scrap 2X4 and a muffler clamp. Sorry, no pictures, but basically it's a strap wrench. The same deal works good removing the PS pulley.

 

awwww...warm fuzzy :-)