Remy 50DN ALTERNATOR DRIVE END FRAME AND SEAL UPGRADE PACKAGE KIT User Manual

Remy Generators

Instruction Sheet

10524489

19JL13 C/P30502 REV3

NOTICE

- Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved

by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
©

DO NOT APPLY ANY

PRESSURE TO SEAL

INSTRUCTIONS TO INSTALL 50DN ALTERNATOR DRIVE END FRAME AND SEAL UPGRADE PACKAGE KIT

WARNING!!!

ALWAYS USE PROPER EYE PROTECTION WHEN PERFORMING ANY MECHANICAL REPAIRS TO A VEHICLE

–

INCLUDING, BUT NOT LIMITED TO, ANY INSTALLATION AND OR REPAIRS TO THE DELCO REMY

ALTERNATORS. FAILURE TO

USE PROPER EYE PROTECTION CAN LEAD TO SERIOUS AND PERMANENT EYE DAMAGE.

DANGER!!!

To avoid injury or damage, always disconnect the negative cable at the battery before removing or replacing the alternator.

The alterna

tor output terminal is always live (“hot”). If the battery is not disconnected, a tool accidentally touching this terminal and

ground can quickly get hot enough to burn skin or damage to the tools and surrounding parts.

Only perform mechanical functions that you are properly qualified to perform. Mechanical repairs that are beyond your technical
capabilities should be handled by a professional installation specialist.

FOLLOW ENGINE OR VEHICLE MANUFACTURER’S INSTRUCTIONS FOR REMOVING THE ALTERNATOR FROM THE ENGINE
AND REINSTALLING.

DISASSEMBLY INSTRUCTIONS:

NOTICE! Do not use an impact wrench to remove or install the pulley nut on the alternator. The impact action of the
wrench can cause damage to the threads on the shaft

1. Mark outer side of pulley so it can be put back on the shaft with the same side out after shaft seal and o-ring are replaced.
2. Hold pulley with a strap-type wrench and use a break-over bar with socket to remove pulley nut from shaft. Remove washer and

pulley from shaft.

3. Remove six (6) retainer plate screws and lock washers.
4. Remove old plate, seal assembly and gasket.
5. Remove old steel spacer and o-ring from shaft.
6. Remove oil line clamp and two (2) screws from stator frame.
7. Disconnect the oil line and remove elbow from drive end (DE) frame.
8. Mark stator frame to later align new DE frame to ensure pad mount alignment is the same.
9. Remove six (6) thru bolts from DE frame and separate old DE frame from stator frame.
10. Press rotor out of the old DE frame.
11. Remove six (6) retainer plate screws and retainer plate.
12. Remove bearings and spacer from old DE frame.

ASSEMBLY INSTRUCTIONS FOR DE FRAME AND SEAL UPGRADE PACKAGE KIT:
NOTICE! The use of anti-seize products on the rotor shaft when reinstalling the pulley is not recommended. It is also recommended
that new bearings be installed with this upgrade kit.

1. Press ball bearing into new DE frame making sure the shield side is towards the rotor.
2. Install retainer plate behind ball bearing with six (6) retainer plate screws and tighten to 5.6-6.8 Nm (50-60 lb in). Stake flat head

screws in place after tightening.

3. Place rotor into DE frame through the ball bearing. Slip on inner spacer and align roller bearing to the DE frame bearing bore.
4. Press entire assembly together until the inner race of the roller bearing has engaged the inner spacer. Make sure that the press tool

contacts both the inner and outer race of the roller bearing. The roller bearing will be pressed down into the bore, unlike the old DE
frame, to allow space for the press in seal. Space between bearings is to be between 1.60 and 1.61 inches.

5. Test rotor to make sure it spins freely.
6. Install elbow fitting with loctite and pre-torque to 15.8 Nm (140 lb in). Continue tightening past pre-torque to bring elbow fitting to

final position.

7. Install oil

plug into drain hole near the front of the DE frame and tighten to 13.6-16.2 Nm (10-12 lb ft).

8. Connect DE frame to stator frame so that the pad mounts are properly aligned as removed. Install and tighten the six (6) thru bolts to

6.8-9.0 Nm (65-85 lb in).

9. Spin rotor to make sure there is no rotor rub with the stator or field coil.
10. Reconnect oil line and install oil line clamp with two (2) clamp screws.
THERE ARE TWO (2) APPROVED OPTIONS FOR INSTALLING THE SEAL KIT:

NOTICE! The use of anti-seize products on the rotor shaft when reinstalling the pulley is not recommended.
Option 1

1. Lubricate the new o-ring with 1948791 bearing lubricate or equivalent.
2. Install new o-ring onto groove on the shaft.
3. Apply Loctite 242 or equivalent to outside diameter (OD) of press-in seal.
4. Align new press-in seal, being careful not to cut the seal on the shaft splines.

FLANGE