One thing you should do when you reassemble the alternator is use anti seize compound on the long steel bolts that hold the unit together.. i.e. the ones that goes through the width of the alternator and thread into the aluminum shell..

I didn't the first time I replaced the brushes on an alternator, and when I did it the second time I had to drill the bolts out as they seized very tightly in the aluminum housing.. <img border="0" title="" alt="[Roll Eyes]" src="images/icons/rolleyes.gif" />

2000 4Runner,V6,Auto,31's, Sliders, Skids, On-Board Air, Air Shocks
Related Interests: Welding, Ham Radio, Road Tripping (Blue Highways), High End Video/Audio Systems