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

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These instructions apply to Delco-Remy 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.

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.

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

Things you will need:

½ 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

1.  Remove the generator from your vehicle according to the steps in it’s service manual.

Warning Always disconnect the cables at the battery before working on your vehicle.

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2. Place disconnected generator onto your workbench.

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.

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.

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.

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.

7. Arrange and reassemble the parts you set aside to help you remember their orientation during reassembly.

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8. Use the proper open end wrench to remove the two thru bolts by turning them counter-clockwise or left.

9. Now remove the collar and cap from the pulley or front side of the generator.

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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.

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12. If you were planning on painting your generator there are a few extra things that need to be done. If you don’t plan on painting then skip to step 20. 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.

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

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.

15. You should end up with something like this. Don’t forget to clean each end cap.

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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 don’t 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.

Your end results should be similar to this.

17. Cover up the internal components so paint doesn’t get into sensitive areas. Also use masking tape to cover any nameplates on the outer shell. Bolt the assembly back together.

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18. Hang the assembly up with string or wire. Make sure there isn’t 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.

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

19. When the paint has dried remove the masking tape and the covering you used to protect the interior.

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20. The next step is removing the old ball bearing. The replacement bearing that came with my kit is a new style that isn’t 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 doesn’t 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.

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24. Take note of the generator diagram at the back of these instructions. It shows the longest side of each brush along it’s 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 o’clock 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. 25. Prep the armature for reassembly by wiping the commutator with the cloth and lacquer thinner or acetone.

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

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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.

27. Now reattach both end caps.

And replace the spacer on the front of the generator.

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.

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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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 doesn’t 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.

30. Replace the lock washer and nut on the shaft. Tighten them with the same method used to loosen them.

31. Follow the instructions in the technical repair manual for the installation of the generator and its initial polarization.

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