One day as I was driving to work the red voltage indicator light came on...so I ignored it and drove that way for three days. It only has 240,000 miles on it. On the second day on my way home from work I stopped into the local auto parts to get the battery/alternator checked. The battery cells checked out fine, but the alternator was only putting out 9.5 volts. No problem, so I kept driving it.
On the morning of the third day the cruiser started to die on the way to work. I turned off the lights and radio and anything electrical and limped into the parking lot at work. Totally dead. Called Toyota dealership to get some numbers. Here they are in no particular order.
Door #1: $700 parts and labor to replace alternator
Door #2: $230 for just the alternator
Door #3: $15 for just the alternator brushes
I am frugal so I chose Door #3. The following is the procedure for saving $685.
Removing the alternator is odd. Yes, I removed the battery tray following removal of the battery. Unbolted the power steering reservoir, and some wires I felt were in the way. The tension/lock bolts were 12mm and the long top bolt was 14mm. Great finesse is needed to coax it out of its home. But once it's out the rest is easy.
1) Remove the three bolts on top + the grounding tab screw
2) Lift the cover and this is what you see. This pic has the new brushes in it.
3) When you unscrew the old brushes there will be a red gasket staring at you. This is as far as you need to go. I went further and unscrewed and cleaned the heat sink as well because my OCD wouldn't let me leave it dirty.
On the morning of the third day the cruiser started to die on the way to work. I turned off the lights and radio and anything electrical and limped into the parking lot at work. Totally dead. Called Toyota dealership to get some numbers. Here they are in no particular order.
Door #1: $700 parts and labor to replace alternator
Door #2: $230 for just the alternator
Door #3: $15 for just the alternator brushes
I am frugal so I chose Door #3. The following is the procedure for saving $685.
Removing the alternator is odd. Yes, I removed the battery tray following removal of the battery. Unbolted the power steering reservoir, and some wires I felt were in the way. The tension/lock bolts were 12mm and the long top bolt was 14mm. Great finesse is needed to coax it out of its home. But once it's out the rest is easy.
1) Remove the three bolts on top + the grounding tab screw
2) Lift the cover and this is what you see. This pic has the new brushes in it.
3) When you unscrew the old brushes there will be a red gasket staring at you. This is as far as you need to go. I went further and unscrewed and cleaned the heat sink as well because my OCD wouldn't let me leave it dirty.
Last edited:
. Total time was 2 hours to complete from start to finishing.
