Alternator Pulley Removal (Help!)

OK, the background to this is in another thread, but time has caught up with me -- have a new alternator to fit, as I'm assuming the old one is dodgy -- and need the truck working tomorrow.

I would have no problem fitting my new alternator, except that I can't get the pulley/fan off the old one.

I can see I need an 8mm hex Allen key (or similar) in the shaft and a 22mm spanner on the nut, but I can't shift it. Is there a trick to doing this, or is it just a case of brute strength (in which case I'm in trouble...)

Incidentally, I don't have a vice big enough to hold the alternator.

(This wasn't a problem when I fitted the last one as it came with the pulley/alternator fitted.)

Advice, please?

best to fit it back on engine - tighten belt, then put a cable tie around the belt below the alternator to really put tension on the belt - you should then be able to loosen the bolt, or if the cable tie does not work put a rope around the belt and make a torneque

shock the nut free by hitting the spanner with a hammer.

ratty said:

shock the nut free by hitting the spanner with a hammer.

Click to expand...

Thanks, Ratty. This ought to work - it's tried and tested.

I just managed to find the really old alternator (removed 2 years ago) to practice on, giving the hammer a bit more welly, but I think whatever is holding the alternator (or pulley) still (eg my hand or foot) is absorbing most of the shock. No sign of movement. Frustrating.

bmp42 said:

best to fit it back on engine - tighten belt, then put a cable tie around the belt below the alternator to really put tension on the belt - you should then be able to loosen the bolt, or if the cable tie does not work put a rope around the belt and make a torneque

Click to expand...

Thanks for this. It's a really clever idea...if it works! I'll stick the thing back in the truck and go from there...

if the old alternator is deffo goosed then you could jam it throught the back (usinga srewdriver) you may need remove the diode pack though

phatwake360 said:

if the old alternator is deffo goosed then you could jam it throught the back (usinga srewdriver) you may need remove the diode pack though

Click to expand...

..well, that's the thing, isn't it? The 'old' one is only 2 years old and I'm not really certain it is faulty at all. (see next post)

Thanks for your help and suggestions guys. It really is appreciated, and especially the quick responses.

I feel I've let you down a bit by not managing to remove the thing, on the other hand, having put the alternator back it is actually charging at the moment, so we must have wiggled something useful. Whether it's doing a good enough job remains to be seen...

(I'd best now go back to the other thread....)

use the non damaging method - it does work

Use a filter strap wrench on the pulley to hold it still.