Stubborn alternator pulley

[jakop92]

So I'm trying to replace the clutched alternator pulley on my ALH... I'm using two box wrenches (12mm to hold center bolt, 17mm to spin pulley counter clockwise) and using two more box wrenches as extensions... and it will NOT budge!

I'm afraid that if I put any more force into it, it might snap the alternator shaft off. I tried spraying with PB blaster, light tapping with a hammer and use of heat gun.. and nothing has worked. Anyone have any tips to get this pulley off without breaking anything??

 

[csstevej]

When I did mine I thought I broke the shaft when it broke loose.
When it does let go you can then spin it off by hand.
And yes , mine let go with a lager snapping sound. My .02.

 

[gquenstedt]

Just keep soaking it with the pb blaster. I use kroil, and they don't come off until the kroil gets all the way soaked in. They say automatic transmission fluid and acetone 50/50 works the best for penetrating lubricant. Could be worth a try.

 

[CopaMundial]

You doing it like this?

https://www.youtube.com/watch?v=qTtvn6LTi04

 

[Genesis]

I have had them come off without too much drama, and then again I had one that I had to remove the alternator and chuck the tool in a vise, then apply a big-freaking breaker bar to the other wrench. I figured if I broke the shaft at that point (or broke the tool) I was no worse off as I was consigned to replacing the alternator in that case.

It came off..... it didn't like it, but it came off.

 

[jakop92]

CopaMundial, that is correct. So really... I have no other option other than to spray it with lubricant and hope for the best? I'm using extensions on both box wrenches, so I'm putting a lot of force on it (i'd say 60-70 ft/lbs), and I'm afraid to put any more force into it. I can definitely give that transmission fluid/acetone mix a go.

Genesis, how'd you manage to get the alternator out? I looked at it, and it appeared to me that either the pulley or the AC unit would prevent the alternator from sliding off the bracket it's bolted onto.

 

[reissue]

I don't condone or recommend this but after plenty of pb blaster and wrench extensions I became furious to the point where I didn't care anymore. I placed the alternator on the ground with one wrench against the floor and the other in the air. After 2 good stomps it came loose surprisingly undamaged

 

[jimbote]

after breaking my center holding tool at a GTG i now remove the alternator or loosen it to the point i can get my impact wrench on it ... i get the alt spinning forward first with the pulley spline tool, then quickly reverse the impact ... spins it off everytime without fear of breaking a bit or wrench

 

[oilhammer]

Yep, on the stubborn ones, a quick zip with the good ol' IR 1/2 impact and they come right off. Lots of times, I have to do it this way because the dust cap was gone and it allowed moisture into the end and rusted up the shaft's internals splines so that the counterhold tool won't properly fit any longer. They can be on there really tight!

 

[d2305]

Make sure you're loosening it the right way. I used a pipe over the ratchet for effect.

 

[Metal Man]

If they are stubborn I hit them on the inner edge with the air chisel (punch) with pressure on the wrenches. I usually find a spot on the car to hold one wrench in place so it is held solid, push with one hand and the chisel in the other.

 

[TDikook]

when I did mine, I had to remove it from the car, put it on the ground and jump on it while I had someone hold it in place(i didn't have an impact gun) it was on there so tight, that when it broke free it made one hell of a bang.

 

[jiggseob]

Use impact...

If you don't have a good air impact wrench, a hammer can be used quite effectively. Let one wrench spin against the body, and hold the other wrench in the direction you need to go. Have a thick glove on the hand holding the wrench. Tap (hit!!) in the direction you want to turn, and it will come off. This method is almost as effective as the air impact. Make sure the spline tool and shaft centre tool are fully and securely seated.

Jiggs