Instructions

For Replacing the Bearing and Brushes in a 1952 Delco-Remy Generator

These instructions apply to DelcoRemy Model 1102776 and 1102777 six volt generators used on the early 50s Nash automobiles. Be sure your generator and generator kit is correct before using these instructions. Replacement of the bearing and brushes will be shown. Other Deloc-Remy generators will be similar but not identical. Also shown is how to prep the exterior for painting.

Things you will need: in. socket set open end wrench set screwdriver set generator rebuild kit 3 jaw gear puller hammer lacquer thinner or acetone lint free rag eye protection breath mask or respirator clean workbench or table small tray gloves wire brush or wire wheel attachment for an angle grinder emery cloth or grinding stone penetrating oil technical service manual for your vehicle

Warning
Disassembly of mechanical components can lead to airborne particles. Wear the necessary safety equipment.

Warning
Painting can be dangerous to your health. Follow the necessary precautions found on the paint can.

1. Remove the generator from

your vehicle according to the steps in its service manual.

Warning Warning
Using power tools can be dangerous. Be sure you know how to properly operate the tool before using it for this project. Always disconnect the cables at the battery before working on your vehicle.

2. Place disconnected generator

onto your workbench.

5. Now the woodruff key in the

shaft needs to be removed. Place a small screwdriver on one end and tap it with a hammer until it comes free. Be careful not to mar the key too badly since it will be reused during reassembly.

3. Begin to remove the pulley by

placing a screwdriver through the fan blades to keep then from spinning while turning the holding nut counter-clockwise or left.

6. Next remove the rubber

connector from the rear of the shaft. The bolt might need some persuasion. Set it aside with the other pieces.

4. Set the nut and lock washer

aside and attach the 3 jaw puller to the pulley. Then turn the bolt on the back of the pulley clockwise or right to remove the pulley from the shaft.

7. Arrange and reassemble the

parts you set aside to help you remember their orientation during reassembly.

8. Use the proper open end

wrench to remove the two thru bolts by turning them counterclockwise or left.

9. Now remove the collar and cap

from the pulley or front side of the generator.

10. Next, look at the orientation

of the brushes at the rear of the generator. Once the armature is removed they will come loose and hang freely. You need to know how they were placed when installing the new brushes. A diagram is provided on the last page. Remove the armature assembly from the main body of the generator. It should pull straight out.

11. Now you can install the new

brushes. Replace them one at a time and make sure the wire alignment is correct. All you need to do here is attach the new wires. The end cap can be removed to make installation easy. A diagram is provided at the back of these instructions that shows their correct orientation.

12. If you were planning on

painting your generator there are a few extra things that need to be done. If you dont plan on painting then skip to step 20.

should be utilized. Follow all guidelines in the use of your tool.

Warning
Using power tools can be dangerous. Be sure you know how to properly operate the tool before using it for this project.

13. Before cleaning the exterior

the outer connections (F or Field and A or Armature terminals) need to be removed. This can be done with an open end wrench. Be careful not to let the bolt twist on the inside of the generator. Wires could be broken if it twists too far. Keep the nuts and washers in order when you set them aside. That way you know the correct order when you put them back on. Once the nuts are removed you can push the bolts down inside the generator out of the way.

15. You should end up with

something like this. Dont forget to clean each end cap.

14. Now you can clean the

exterior of your generator. Pictured is an angle grinder fitted with a abrasive wire wheel. Any abrasive can be used to remove the rust and grime from the exterior. Hand, eye, and respiratory protection

16. There are still residue and

fine particles on the surface. To clean them off use a lint free rag and a solvent like lacquer thinner or acetone. Gloves should be used here to protect your hands. Do this near ventilation or outside so the fumes dont build up. Pour some on the rag then rub where you want cleaned. Do this until you are satisfied that it is clean enough for paint.

17. Cover up the internal

components so paint doesnt get into sensitive areas. Also use masking tape to cover any nameplates on the outer shell. Bolt the assembly back together.

Your end results should be similar to this.

18. Hang the assembly up with

string or wire. Make sure there isnt anything nearby to get overspray on. Use an engine primer first to establish a good base for the paint to stick to. Follow the instructions on the can. Make sure you allow adequate time for the paint to dry. This is the longest step.

19. When the paint has dried

remove the masking tape and the covering you used to protect the interior.

Warning
Painting can be dangerous to your health. Follow the necessary precautions found on the paint can.

20. The next step is removing the

old ball bearing. The replacement bearing that came with my kit is a new style that isnt required to be oiled. Remove the 3 screws and the cover over the backside of the bearing. Save the gasket. Compare the sizes of the new and old bearings. They should be exactly the same. Use the penetrating oil around the outside of the bearing race. Give it a minute or so to soak then just pull it out. If it doesnt come out just pulling with you finger tap it a few times with a chisel or punch and a hammer.

21. When the old bearing is

removed you will find a felt o-ring and a backer. Your new bearing will not need these but leaving them out will allow dust and dirt to collect next to the bearing. Make sure you put them back in if you remove them for any reason.

22. Reinstall the felt o-ring and

backer from the last step. Wipe away any penetrating oil that is left over where the bearing seats. Test fit the new bearing and make sure the outer race cannot spin. If it does spin apply a small amount of Permatex Blue RTV gasket maker to the outer bearing race. It may be necessary to use a wood block and hammer to tap the bearing until it is fully seated.

23. Reassemble the gasket and

bearing cover.

24. Take note of the generator

diagram at the back of these instructions. It shows the longest side of each brush along its backer. The generator rotates clockwise when viewing it from the rear so the long sides of the brushes will be on the 12 and 6 oclock sides respectively in the picture to the right. They will only go in and work one way. Refer to any observations you took before they were disassembled.

Now you can place the armature back into the main body of the generator taking care to keep the brushes in the correct orientation.

25. Prep the armature for

reassembly by wiping the commutator with the cloth and lacquer thinner or acetone.

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26. Now place the field and

armature terminals back in their positions and place the nuts and washers back on in the proper order.

28. Clean up any rough edges on

the woodruff key with a grinding wheel or emery cloth. This helps it go into the shaft cleanly.

27. Now reattach both end caps.

And replace the spacer on the front of the generator.

Reinstall the woodruff key in the shaft. The best way to do this is center it then gently tap it with a hammer until it is fully seated. Be careful not to distort it.

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30. Replace the lock washer and

nut on the shaft. Tighten them with the same method used to loosen them.

29. Once the key is seated you

can reinstall the fan/pulley assembly. Make sure the groove lines up with the key then slide it on. If it doesnt slide all the way on then take a large socket that will fit around the shaft and tap it until it bottoms against the spacer.

31. Follow the instructions in the

technical repair manual for the installation of the generator and its initial polarization.

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