alternator pulley removal 1985 300D Turbo

[Geotiger]

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.

[Kyle Blackmore]

Sometimes they'll break loose if you give them a good whack on the arbor, a puller might distort the pulley. Good luck.

[jbaj007]

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.

[300SDog]

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.

[carusle]

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.

[Jkid]

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.

[Geotiger]

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.

[babyjames]

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

Jay.