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Old 11-27-2006, 10:13 PM
Geotiger's Avatar
Join Date: Aug 2006
Location: Hoover, AL
Posts: 13
alternator pulley removal 1985 300D Turbo

Hello all:

Frequent reader, infrequent poster. I've searched this forum and another for the questions below but can't find any.

This past weekend I pulled the Bosch alternator after the bearing(s) went south and broke both alternator belts. I've removed the nut that secures the pulleys but cannot figure out how to remove the pulley and fan to use on the new alternator. Any help would be greatly appreciated.

'85 300D Turbo MB
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Old 11-27-2006, 11:39 PM
Kyle Blackmore's Avatar
Mostly Harmless
Join Date: Sep 2001
Location: almost beyond Hope...B.C.
Posts: 897
Sometimes they'll break loose if you give them a good whack on the arbor, a puller might distort the pulley. Good luck.
1985 380SE- 160,000km 'Blistu' - Sold
1988 300CE- Eva,my garage mistress
2007 R350 4matic- The Black Pearl
2011 Ford Ranger-Work truck
1974 25' Trojan Sea Raider- 'Grannyknot'
2002 215 cm Atomic DH skis- Canadian SDH record holder, 175.5km/h- Vars 2010
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Old 11-28-2006, 12:24 AM
jbaj007's Avatar
Registered User
Join Date: Jun 2001
Location: Santa Monica, CA
Posts: 2,053
I use an air impact wrench; only thing that is a gauranteed for me. If you don't have air tools, take it to the gas station/garage nearby and they'll usually "rattle" it off for you.
The Golden Rule

1984 300SD (bought new, sold it in 1988, bought it back 13 yrs. later)
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Old 11-28-2006, 01:49 AM
300SDog's Avatar
gimme a low-tech 240D
Join Date: Jan 2003
Location: central ky
Posts: 3,602
There is a woodruff key that holds the pulleys. Shoot it heavily with penetrating oil and let it marinate. Then smack the pulleys with a rubber hammer and they should loosen up.
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Old 11-28-2006, 10:49 AM
Registered User
Join Date: Mar 2006
Location: Conyers, Ga.
Posts: 137
I used a 3 prong gear puller on mine, but it was way too easy. A shot of PBS and the hammer would have done it. Don't loose the key, and get all of the washers and parts back in the same order.
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Old 11-28-2006, 11:03 AM
Registered User
Join Date: Jan 2006
Posts: 172
Make sure you use an impact wrench to install the pulley / nut as well. I made the mistake of thinking that the nut just needed to be snug and that the key would keep the pulley from spinning on the shaft. Not so, that nut needs to be tight! Fortunately for me the 300SD can run for a long time without an alternator or water pump in the winter. Unfortunately I have a nice ding in my otherwise perfect hood from where my alternator shaft / fan blew up on me.
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Old 11-28-2006, 01:37 PM
Geotiger's Avatar
Join Date: Aug 2006
Location: Hoover, AL
Posts: 13
Thanks for the good advice from everyone. I used WD-40 on the key 2 days ago, and I'm trying the pulley remover today. If it doesn't work, I'll try my regular mechanic.

'85 300D Turbo MB
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Old 11-28-2006, 01:42 PM
Registered User
Join Date: Apr 2005
Location: Pac NW
Posts: 690

A little blue loctite goes a real, long way. Use it for everything you don't put anti-seize on.

On the road, currently:
'83 300D (German spec.) 168k mi. - - Wolfgang (tucked snugly away for the winter!)
'87 300D 375k mi. - finally went over to "The Dark Side"
'87 300TD 225k mi.
Cannondale 66cm CAAD5 w/Campy/Jamis Aurora
Hujsak Custom Fixie/Landshark Track Shark Custom/Ahearne Custom 29'er
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