Alternator bearing sleeve, brush holder, and cap system

An assembly (30) for use with a rotating electric machine has a first injection-molded plastic part (32), a second injection-molded plastic part (34), and a third injection-molded plastic part (36). Parts (32, 34) are a bearing sleeve and a brush holder respectively, while part (36) is a cap. The bearing sleeve has a transverse wall (138) from which channels (146, 148) extend in one direction. A cylindrical wall extends in the other direction to form a bearing cup (136) for receiving a bearing assembly. The brush holder has two side-by-side brush guides (62, 64) each containing a respective brush (38, 40). It also has two channels (110, 112) that interlock with the channels of the bearing sleeve to accurately and rigidly place the two parts (32, 34) in assembly. The cap closes an axial end of the bearing sleeve and attaches to the brush holder. The parts are further characterized by various structural features, as well as fabrication and assembly methods.