Toyota 27700-20050 Regulator Assy, Generator

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Place the alternator on a clean bench. Remove the output terminal nut, insulator, rear cover, and brush holder. Detach the voltage regulator. Measure each brush's length, replace if below minimum. Ensure smooth brush movement. Reinstall the voltage regulator, brush holder, and rear cover. Secure the output terminal insulator with the nut. Reinstall the alternator.

To do this, disconnect and then unbolt the alternator, then clean it by laying it on a workbench. Unscrew the output terminal nut and the insulator; unscrew the nuts on the rear cover and take the rear cover off. Subsequently, unscrew the two screws that hold the brush holder and join the holder from the battery assembly. Next, pull out the three screws that hold in the voltage regulator and take out the voltage regulator, however, as you can see refer the models 2007 and onwards do not have these voltage regulators as explained. Calculate the length of all exposed parts of each brush and match that with the set length minimum; in a situation where the encountered length is less than the minimum, change the brush assembly. Make sure that every single brush to slide in the brush holder with equal ease. Move on to fit the voltage regulator then the brush holder; the brushes should be pushed in by using a small screwdriver while fitting this part to clear the shaft. Screw the brush holder to the back frame Next, fit in the back cover and tight the nuts down as much as possible. Last but not the least fix the output terminal insulator and fasten it with the help of the nut and fit the alternator.

Install the voltage regulator.