Alternator pulley education

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fpchief

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Dealing with an alternator that someone gave me. it has a different pulley than the one I have that is bad. I was able to pull the pulley off of the one that came off my M1097a2, to put on the newly acquired one but cant get the pulley off. The 3 jaw puller won't fit behind it. Before I get the grinder out on my puller, I figured it best to see if I may be using the wrong tool. Alternator in foreground is the one I am trying to pull pulley off. The alternator in background came off the hmmwv and needing to use its pulley...they have different standoffs from alternator body.
 

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NDT

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Does the pulley have threaded holes? If so get some grade 8 bolts, thread them in and attach the puller jaws to the head of those.
 

fpchief

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Going to try chain vise grip wrapped around the pulley and that should be large enough of a surface so the claw puller can grab hold.

I cant take credit for that excellent idea. A friend in Midland City, Al. Came up with that.
 

Retiredwarhorses

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The fixed pulley is for early serp setup, the clutch pulley is for latest style, this allows the generator to continue spinning when the engine is turned off, this preventS premature shaft failure And belt jump off.
 

fpchief

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Are they both supposed to be tracking the same or is there offset? They do not look like they would track the same on the other pulleys. I believe the outside edge of the solid pulley is about. 5" farther out than the clutch pulley.
 

Retiredwarhorses

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They Both have to used on there specific serpintine setup, that are not compatible across the two
different serp set ups. The TM will show you the correct UOC and truck SN range.
 

fpchief

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Well, almost to the point of being desperate to get this pulley off. This is the last thing keeping the HMMWV from cranking. I ended up ruining this clutch pulley, did not mean to but this thing just wont release from the shaft. Now, this is what is left on the shaft.....I tried chain vise grips and a puller to yank this off but it wont grab enough and keeps slipping. Need some ideas. There is PB down in that groove soaking still.
 

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NDT

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At this point, weld on a couple ears for your puller to grab onto. The weld heat will assist with opening up the clearance on the shaft.
 

fpchief

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At this point, weld on a couple ears for your puller to grab onto. The weld heat will assist with opening up the clearance on the shaft.
That what I was gonna do incognito, but since you mentioned it, the welder is about to crank up.
 
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