4-2. ALTERNATOR PULLEY REPLACEMENT
This task covers:
a. Removal
b. Installation
a. Removal
1.
Clamp alternator pulley (2) in a soft-jawed vise.
2.
Remove locknut (5) and washer (4) from alternator shaft (3). Discard locknut (5).
3.
Remove pulley (2) from soft-jawed vise.
4.
Using a mechanical puller, remove pulley (2) from alternator (1).
5.
Remove woodruff key (6) from alternator shaft (3). Discard woodruff key (6).
INITIAL SETUP:
Tools
General mechanic’s tool kit:
automotive (Appendix B, Item 1)
Maintenance and repair shop equipment:
automotive (Appendix B, Item 2)
Mechanical puller (Appendix B, Item 157)
Vise inserts (Appendix B, Item 160)
Materials/Parts
Locknut (Appendix G, Item 110)
Woodruff key (Appendix G, Item 470)
Manual References
TM 9-2320-387-24P
Equipment Condition
Alternator removed (para. 4-5).
Maintenance Level
Unit
b. Installation
CAUTION
Serpentine belt failure (abnormal wear or belt dislodgement) can
be caused by misalignment of pulleys, improper installation, or
foreign objects introduced into belt path. Inspect water pump
pulley for proper installation and ease of rotation. Any wobble or
misalignment will cause belt failure.
1.
Position woodruff key (6) in alternator shaft (3) with flat side up.
2.
Align pulley keyway (7) with woodruff key (6) in alternator shaft (3) and tap pulley (2) onto
shaft (3).
3.
Install washer (4) and locknut (5) on shaft (3). Tighten locknut (5) finger-tight.
4.
Clamp pulley (2) in soft-jawed vise.
5.
Tighten locknut (5) to 115-125 lb-ft (156-169 N•m).
6.
Remove pulley (2) and alternator (1) from vise.
TM 9-2320-387-24-1
4-2
Change 1
