TM 9-2320-280-20-2
4-3. ALTERNATOR PULLEY REPLACEMENT
This task covers:
a. Removal
b. Installation
INITIAL SETUP:
Tools
Manual References
General mechanic’s tool kit:
TM 9-2320-280-24P
automotive (Appendix B, Item 1)
Mechanical puller (Appendix B, Item 167)
Equipment Condition
Vise inserts (Appendix B, Item 170)
60 amp alternator removed (para. 4-2).
Materials/Parts
100 amp alternator removed (para. 12-23 or 12-24).
200 amp alternator removed (para. 4-109 or 4-110).
Locknut (Appendix G, Item 59)
Woodruff key (Appendix G, Item 245)
NOTE
The removal and installation procedure for 60 amp, 100 amp, and
200 amp pulleys are identical.
a. Removal
1. Clamp alternator pulley (2) in a soft-jawed vise.
2. Remove locknut (4) and washer (3) from alternator shaft (6). Discard locknut (4).
3. Remove alternator (1) and pulley (2) from soft-jawed vise.
4. Using a mechanical puller, remove pulley (2) and woodruff key (5) from alternator (1). Discard
wooodruff key (5).
b. Installation
1. Position woodruff key (5) in alternator shaft (6) with flat side up.
2. Align pulley keyway (7) with woodruff key (5) in alternator shaft (6) and tap pulley (2) onto shaft (6).
3. Install washer (3) and locknut (4) on shaft (6). Tighten locknut (4) finger tight.
4. Clamp pulley (2) in soft-jawed vise.
NOTE
For 200 amp alternators (12338796-1), tighten locknut to 115-125
lb-ft (156-169 N.m).
5. Tighten locknut (4) to 95 ± 5 lb-ft (129 ± 7 N.m).
6. Remove pulley (2) and alternator (1) from vise.
4-8
