Join Date: Aug 2018
Location: Springwood, Qld, Australia
Did mine last week
I researched how to remove the alternator pulley and found that the pulley removal kits do not work for our type of alternator. My local shop quoted AUD$350 to remove and fit a new pulley. They told me I wouldn't be able to get the pulley off myself, we will see about that!
I bought the pulley from Autobarn and fitted it myself for AUD$69.00. Had to remove the alternator from the vehicle to replace the pulley.
To remove alternator, top bolt removes from the front and the more difficult one from the bottom rear of the alternator.
Before tackling the pulley I sprayed WD40 in to the thread area to help with getting it off.
I then used a 17mm inhex socket with a rattle gun and just held the pulley with my hand and gave the gun a few hits, came of easily despite the alternator spinning. I guess the sharp knock of the rattle gun overcomes the fact that the rotor also spins at the same time. Did the same for replacing.
I was not at all keen to wedge something in the alternator to prevent it spinning as the rattle gun runs a chance of bending fins or damaging wiring.
Replacing the alternator was the most difficult part of the job. Trying to line up the bottom lugs of the alternator so the long bottom bolt can be reinserted. You can't see where it goes to line it up and must do it by feel. Best to put the top bolt back in and leave it loose while you swing the alternator back into position to get the bottom bolt back in. While I was at it I replaced the two idler pulleys and the power steering belt and serpentine belt.
D40 Automatic Diesel. 2" lift, Bull Bar, Spot lights, Dual Battery, Waeco 60lt Fridge, UHF radio, rear conopy, scan guage, on board air compressor, turbo timer, had a DP Chip but changed to Steinbauer, ERPS 8 pad rust preventative system, Nissan snorkel, rear shelf in canopy/tub and Tekonsha brake contoller.