Help! 2001 Alternator Pulley Removal
Thread Starter
5th Gear
Joined: Mar 2005
Posts: 5
Likes: 0
Help! 2001 Alternator Pulley Removal
Thanks for the responses so far ...However this monster has the clutch style pulley. The bolt, torx, not nut, is recessed about 1.5 inches. There are splines around the ID of the cavity going with the bolt at the bottom. I have gotten on it and it won't budge. Has anyone been able to remove the pully? Even the dealership won't touch. Also, any tips on getting at the front bearing to replace. Thanks
Last edited by pittmanp; Mar 29, 2005 at 12:45 PM. Reason: The 01 Has a clutch style pully
Le Mans Master
Joined: Jan 2001
Posts: 5,786
Likes: 6
From: Lafayette Colorado
It is pretty easy to remove if you have a belt wrench. I got a rubber belt one from a local auto parts store for about $10.
1) remove the belt.
2) place the belt wrench around the pulley
3) place the correct size socket on the nut holding the pulley on
4) turn the socket wrench counter clockwise and the belt wrench clockwise
Once the nut is loose, it will come off by hand. After that the pulley slides right off.
Keith
1) remove the belt.
2) place the belt wrench around the pulley
3) place the correct size socket on the nut holding the pulley on
4) turn the socket wrench counter clockwise and the belt wrench clockwise
Once the nut is loose, it will come off by hand. After that the pulley slides right off.
Keith
Le Mans Master
Joined: Jan 2001
Posts: 5,015
Likes: 508
From: Hilton NY
The pulley design sucks. I used the closed side of a box wrench to hold the nut but had to grind some of the wrench handle so it would sit low enough to just hold. A Torks socket can fit the inside of the shaft. After the pulley was removed it was put on a lathe and the nut area was opened up so a wrench will fit better. One bearing is held in the case by four screws and retainer, the bearing will tap out easily. The other bearing is pressed onto the rotor shaft, a puller should get it off.
Burning Brakes
Joined: Aug 2000
Posts: 1,132
Likes: 1
From: Morganton, NC, USA
The bearings should be packed with a good quality ball and roller bearing grease, like Cheveron BRB or SRI. Grade 2. Do not use chassis lube grease. If you buy a sealed or shielded ball bearing off-the-shelf, it will be pre-packed, but maybe not with the good grease. If you can find an alternator shop, they'll have the correct bearings and the tools to R & R. Check the brushes at the same time and replace also: cheap insurance. Usually alternators fail because: 1. The grease or bearing goes bad; 2. The brushes wear down; or 3. An electronic component, like a diode, fails. 
Pro
Joined: Dec 2000
Posts: 747
Likes: 0
From: Columbia SC
pittmanp,
I take the new style ALTs apart all the time. It does require a specialty tool to remove the clutch style pulley. This will cost you as much as the ALT. Depending on your plans from there, getting into the ALT isn't easy either. You will ruin all of the diodes that are welded into the case and need to replace them prior to reassembly. And this is only part of your problems........... Email me at: dtsngit@bellsouth.net if you want to discuss your plans or for help.
Mike
I take the new style ALTs apart all the time. It does require a specialty tool to remove the clutch style pulley. This will cost you as much as the ALT. Depending on your plans from there, getting into the ALT isn't easy either. You will ruin all of the diodes that are welded into the case and need to replace them prior to reassembly. And this is only part of your problems........... Email me at: dtsngit@bellsouth.net if you want to discuss your plans or for help.
Mike
