If you encountered burned insulation, chipped varnish coating, cracked IC, like the alternator involved in this write up, better go surplus or trade it in with a reman unit as a cheaper and way lot easier route.

So here is the exploded view of the alternator. Starting from the right (order of install): Rear housing, 2 pcs oil seals, diode assy, VR unit, stator, rotor, front bearing retainer, front bearing, front housing, pulley, lock washer and nut. some may include spacers in between housing and pulley.


Rebuilding the vacuum pumps (diesels) is very easy. just replace the 2 pieces of O-rings and some copper gaskets. One on the front housing of the vacuum pump where it mates to the rear of the alternator. The other one is the bigger O-ring in between the rear and front pump housing (see pic). Copper gaskets on the check valve and oil supply and return lines.



Enjoy and HTH.