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HOMESERVICE MANUALSCHEVROLET1996TAHOE 2D UTILITY, 6.5 SREPAIR AND DIAGNOSIS (SINGLE PAGE)ELECTRICALCHARGING SYSTEMSCHARGING SYSTEM - CS-144INSPECTION & REPAIRCLEANING & INSPECTIONINSPECT
1996 Chevrolet Tahoe 2D Utility, 6.5 S

Cleaning & Inspection: Inspect

1996 Chevrolet Tahoe 2D Utility, 6.5 SSECTION Inspect
  1. Inspect brush holder for damage. Clean brush holder. Make sure the brush pockets are clean. Clean brushes with a soft dry cloth.
  2. Inspect brushes for wear. If the brushes are worn to 11 mm (0.4 in.) or less in length, replace the brush holder assembly. Use a retainer pin to hold the brushes in the holders.
  3. Inspect brush springs for broken wire or corrosion.
  4. Inspect slip ring end of the rotor shaft for overheating or scoring. If signs of overheating or scoring are present, replace the rotor. The slip ring end bearing must be replaced any time the two halves of the generator are separated.
  5. Inspect drive end bearing for roughness, looseness, or wear. If the condition of the bearing is in doubt, replace it.
  6. Inspect windings for burned insulation. Replace the rotor or stator if either looks burned. Burned insulation appears as very dark or blackened wiring. A strong acidic odor will be apparent.
  7. Inspect terminal connectors for corrosion or breaks.
  8. Inspect windings on the stator for chipped insulation. If the chipped area is small and the rest of the stator is OK, repair the stator with insulating varnish.
  9. Inspect slip rings for scoring, wear or pitting.
    1. If the rings are dirty, clean with a 400 grain or finer polishing cloth.
    2. Spin the rotor and hold the polishing cloth against the slip rings until they are clean.
    3. If scored, worn, or pitted, true the rings in a lathe to 0.05 mm (0.002 in).
    4. Finish with 400 grain or finer polishing cloth. Blow away all dust.
  10. Inspect rotor and stator windings electrically as described under "Electrical Tests," in this section.
  11. Inspect generator housing for cracks, warping, or other damage.
  12. If the regulator, brush assembly, or connector needs replacing, it will have to be unsoldered from the other two components. Use as little heat as possible to protect the regulator. See Fig 1.
Fig 1: View Of Regulator Connections
G00403541Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.