Replacing alternator pulley. (1 Viewer)

[esoniat]

Two questions.
1. how do you get the pulley off the shaft
2. how do you get the nut tight when assembling the pulley.

In way of explanation.
I have a replacement alternator which has a pulley that is two narrow.
I am on the road and have only hand tools.
I have removed the nut on the new alternator but can not get the pulley off the shaft.
I since I couldn't get the pulley off I decide to put the nut back on but I can not get tight.
The shaft turns inside the fan if I hold it and if I use an allen wrench to hold the shaft I can not get it any tighter even if I use a cheater on the allen wrench.
Fortunately my old alternator responded to lubrication and is quite now but I really need to replace it for reliability.

I did do a lot of searching before posting and all I find is discussions on how to loosen the nut.

 

[Mark W]

Air impact.

Mark...

 

[WILLD420]

An impact wrench is the only way to get it done. If you can hold the Allen tool steady enough, you can use a hammer on the wrench tightening the nut. Takes three hands and patience.

 

[FJ60Seth]

To remove the pulley from the shaft, remove the alternator and suspend it loosely in a vice so the pulley is resting on some wood blocks. Lift the alt a little bit and very gently let it drop on the blocks. The pulley will slide off.

 

[esoniat]

An impact wrench is the only way to get it done. If you can hold the Allen tool steady enough, you can use a hammer on the wrench tightening the nut. Takes three hands and patience.

Looks like I'll have to find a shop to do it for me some where along the road, fortunately my old alternator is still working.

 

[g-man]

I recently found my alt. pulley to be loose on the shaft. When I tried to tighten the bolt the rotor shaft just spun with the nut and I couldn't tighten the pulley down on it. Even hitting it with an impact wrench the rotor spun. The FSM says to remove the back of housing and put it in a vise with rubber grips to protect the back of the rotor and then tighten the *edit nut on the pulley. I did this and it worked but when you remove the backing realize that there are two brushes that will pop out of their holes cause they have small springs underneath. They should stay with the alternator because (edit) a copper wire holds them that is soldered to the back side of the brush pack. But there is a trick to getting them back in their holes. Their is a small hole in the back of the alternator housing that you put a wire through. (edit) Each brush is pushed down so the top of the brush is about 1/4" into the hole and the wire runs across the top of the brush holding it in position. Use forceps or a any small 90 degree tool to push them down into the hole. Thread the wire ( i used a straightened paper clip)over each brush, one at a time. This will hold the brushes in the holes so you can put the rotor back in the backing. Then remove the paper clip. No impact required.

 

[g-man]

this:

 

[g-man]

I used a welding glove in the vise to protect it.

 

[Mark W]

A good thick leather glove (welding glove) to grip the pulley/fan by hand and short burst of impact from the gun and they always come off for me. It may be the factory way, but taking the alternator apart would be my last choice of desperation.

Mark...