Removing alternator pulley

[Oscarthegrouch]

I removed the nut, but the fan/pulley isn't budging.  Is it just friction and rust holding it on there?  I can try some heat and a puller but I want to make sure I'm not missing a pin someplace.  Thanks for all the great info, I've been using this forum for a while but this is my first question.

 

[Mikesmalaga72]

Grab 2 screwdrivers or plastic trim tools and gently wobble the fan and pulley off of the keyway and shaft it should come right off perhaps get some penetrating oil first, once you see any wobbling try using your hand to wobble it the rest of the way off. Note: assure the key is still pressed in the slot.  

['76mintgrün'02]

Sometimes shock helps.  You could try putting a socket over the shaft, with it resting on the pulley and smack it with a hammer a couple of times.  It doesn't have to be a big hammer.  (I keep crappy sockets around for stuff like this).

[jimk]

I hold the alternator shaft vertical and by the fins and hit the shaft with a dead blow hammer.  Have a pad under it because the alternator is going to drop out of the fan.

[Oscarthegrouch]

Thanks.  The hammer loosened it a bit, and the screwdrivers were able to work it off.  Took a lot of force, I was concerned about deforming the fan/pulley assembly.

 

A retaining clip magically appeared.  The retaining clip from the bushing came off in the process.  Very confusing for about 20 minutes.   I've had no luck finding an assembly diagram for the AL89X.  But that's what makes this fun, right?

Edited December 26, 2023 by Oscarthegrouch

[Mikesmalaga72]

You may want to replace those rubber bushings in the case front with delrin or polyurethane the rubber gets flimsy rather quickly. Your call tho. 

[Oscarthegrouch]

I'm moving the pulley to a remanufactured alternator with fresh bushings.   You can see it in the back in the top pic.  Also replacing the belt.  Thanks for looking out for that.