2004 Subaru Baja Base, AutomaticFACTORY OEM SERVICE PROCEDURE

Generators & Regulators: Overhaul: Generator: Disassembly

  1. Remove the 4 through-bolts shown in Fig 1 .
  2. Heat the portion (A) of rear cover to 122°F (50°C) with heater drier. See Fig 2 .
  3. Insert the tip of a flat-head screwdriver into the gap between the stator core and front cover. Pry them apart to disassemble. See Fig 3 .
    CAUTION: To prevent rotor damage when holding rotor with vise, insert aluminum plates or wood pieces on vise's contact surfaces.
  4. Hold rotor with a vise and remove pulley nut. See Fig 4 and Fig 5 .
    CAUTION: Rectifier cannot withstand heat well. Finish below steps rapidly (less than three seconds).
  5. Remove the ball bearing as follows:
    1. Remove bolt, then remove bearing retainer. See Fig 6
    2. Firmly install to bearing inner race an appropriate tool, such as a fit socket wrench. See Fig 7 .
    3. Push the ball bearing off the front cover using a press.
  6. Remove bearing from rotor using a bearing puller. See Fig 8 .
    CAUTION: The rectifier cannot withstand heat well. Do not allow the 180-270 watt soldering bit to contact the terminals for more than 5 seconds at a time.
  7. Unsolder connection between rectifier and stator coil to remove stator coil. See Fig 9 .
  8. Remove IC regulator as follows:
    1. Remove screws that secure the IC regulator to the rear cover. See Fig 10 .
    2. Unsolder connection between IC regulator and rectifier to remove IC regulator. See Fig 11 .
  9. Remove brush as follows:
    1. Remove cover A. See Fig 12 .
    2. Remove cover B. See Fig 13 .
    3. Separate brush from connection to remove. See Fig 14 .
  10. Remove rectifier as follows:
    1. Remove bolts that secure rectifier. See Fig 15 .
    2. Remove terminal B's cover. See Fig 16 .
    3. Remove nut from terminal B. See Fig 17 . Remove rectifier.
Fig 1: Removing Front Cover Through-Bolts
G00214897Courtesy of SUBARU OF AMERICA, INC.
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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.