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Author Topic: Alternator Pulley removal???????????  (Read 1003 times)

Offline Peter Burgess

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  • Model: Galaxy Mk2
  • Spec: 1.9 diesel Zetec
  • Region: London
Alternator Pulley removal???????????
« on: September 23, 2018, 03:07:03 PM »
So I bought a new pulley & the proper removal tool set, but the pulley wouldn't budge.

So I filled the cavity with "Plus gas" & left it to soak for 48 hours, but still no joy!

I then reluctantly got out my Clarke Impact wrench, pushing the spanner anti clockwise & the impact wrench running forwards on the alternator shaft & left it running for 30 seconds --- nothing!

I then heated up the pulley with a good blow torch until the puddle of plus gas was smoking & tried the impact wrench & spanner again, but to no avail!

I'm now thinking of cutting the pulley with a small angle grinder across the grooves & trying to split the pulley with a cold chisel (supporting it underneath to avoid bending the shaft).

Is this a bad idea?

can anyone suggest something helpful that I haven't tried?

Thanks,

Peter.

Offline Chrispb

  • Mindsaysyesbodysaysnono
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  • Spec: 52reg TDI 115 Ghia
  • First Name: Chris
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Re: Alternator Pulley removal???????????
« Reply #1 on: September 23, 2018, 03:49:08 PM »
Sound like your turning it the wrong direction.
The pulley is unscrewed by turning pulley clockwise and turning shaft anticlockwise.
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2003 MK2 Galaxy Ghia In Solid Black 1.9 TDI 115PS. 5 Speed Automatic.

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Offline johnnyroper

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  • Spec: 02 tdi 115 ghia
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Re: Alternator Pulley removal???????????
« Reply #2 on: September 23, 2018, 03:55:44 PM »
I don’t remember mine being left hand thread when I did it?? Sure shaft was clockwise and pulley counter clockwise?
Was super tight mind with corrosion in threads. Had to use 2 spammers linked for leverage and breaker bar in the shaft.

If it still won’t budge I would be more inclined to get a recon alternator as I suspect cutting and chiselling will cause damage to shaft/bearings

Offline regw

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  • Model: Galaxy Mk2
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  • First Name: Reg
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Re: Alternator Pulley removal???????????
« Reply #3 on: September 23, 2018, 04:23:38 PM »
Did mine recently and it was reluctant to move at first
I did the old trick of tightening it a bit first before loosening.
in fact I ran the thing back and forth a few times before
going at it full whack and it came off in time

Incidentally those Clark impact wrenches are not all they're cracked up to be
I bought one and it wouldn't remove my wheel studs so I had go at it in the old fashioned way
with a long bar
You may want consider a long/er bar on the alternator 
« Last Edit: September 23, 2018, 05:02:36 PM by Chrispb »

Offline Peter Burgess

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  • Model: Galaxy Mk2
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Re: Alternator Pulley removal???????????
« Reply #4 on: September 23, 2018, 06:45:50 PM »
I have tried a long bar wedged to the floor & standing on the spanner, but the shaft holding tool twists alarmingly, to the point I fear it might break!

Offline regw

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Re: Alternator Pulley removal???????????
« Reply #5 on: September 23, 2018, 07:04:01 PM »
No luck running the Clark tool back and forth?
If I got desperate enough to cut it off I'd get a thin INOX type 1mm cutter blade
in the angle grinder and make two diametrically opposed diagonal cuts across the pulley grooves to within 1mm or so of the
threads then ever so gently continue with a hacksaw so as not damage the shaft threads.
When i felt I was close breaking through, I'd carefully use the chisel
I'd also take my time so as not build up excess heat in the shaft and cover/protect the alternator from
the sparks and grit.
I've had to do similar before and found taking my time, steady progress got the best results
Rushing and heavy handeness usually got tears before bedtime :-)

Offline regw

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  • First Name: Reg
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Re: Alternator Pulley removal???????????
« Reply #6 on: September 23, 2018, 07:07:09 PM »
In fact if you weaken it enough it will probably fall apart if you use the removal tool on it after

 

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