TM 5-4240-5501-148PALTERNATOR11/2 AmpFig. 158 - Testing RectifierFig. 159 - Testing Rectifier (Alternate Style)Replacing RectifierCut stator wires close to rectifier so that stator wiresremain as long as possible. Discard old rectifier. Stripinsulation back 3/8" from stator wires. Replacementrectifier has two exposed wires which are alreadystripped of insulation. Twist and solder each stator wireto a rectifier wire. Insulate each connection withelectrical friction tape, keeping connected areas ascompact as possible. Remove and discard originalground wire from drive housing. Fasten new ground wireto drive housing. Locate wires as shown in Figure 160.Retest rectifier as shown in Figure 158 or 159.Fig. 160 - Replacing RectifierReplacing Defective Rectifier BoxRemove rectifier box from starter motor. Use ascrewdriver to pry under the fiber board as shown inFigure 161. Fiber will break, exposing solderedconnections between rectifier and stator leads. Cutstator leads close to eyelets so stator leads remain aslong as possible. Strip insulation back to expose about3/8" of wire. Discard defective rectifier box.Fig. 161 - Replacing RectifierReplacement rectifier box has short leads, the tips ofwhich are already stripped of insulation. Twist and soldereach stator lead to a rectifier lead. Insulate eachconnection with electrical friction tape, keeping splices ascompact as possible because of small space available.Form splices into bottom of rectifier box as shown inFigure 161. and re-assemble rectifier box to startermotor. Pull gently on leads to insure a firm connectionand locate them as shown in Figure 161. so they cannotrub on flywheel ring gear. Recheck output as shown inFigure 153.50
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