Got my replacement Bosch alternator from fastlane last night. Quick service, and good price. They are offering free shipping now also.
Question is what is the easiest and most damage free way to remove the pulley and fan from the old alternator? Been a long time since I did that one.

Old Deis

Use an impact wrench. BTW do you have a front euro bumper or any rubber of same for sale?

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1985 Euro 240D 5 spd 140K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"

IMHO, it's getting some penetrant on, then having a tight fitting wrench on the nut, striking quickly. Do it with the old alternator still on the car, with full belt tension holding the pulley from rotating

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'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.

I've always been able to get them off by holding the pulley while wearing leather work gloves, then hitting it with the impact gun.

Kevin

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'85 300SD

Stevo- I do have an 81 300D Euro parts car, but is was hit hard on the rt front. I doubt the frt rubber is intact, but will check it. The metal parts in frt are definately ruined.
Have an impact wrench and some good penetrant. Will get to work on the alternator.
Thanks.

Let me add something even more important. Be sure to torque the nut down to the proper spec on the new alternator. 35-45 nm for multi-belt pulley and they use a strap type wrench to hold the pulley. I'd probably even go with some loctite blue, just to be sure. This is a real bad case of of the DIY mantra "don't ask me how I know".
Hint: you really can drive for 50 miles at 65 mph on the expressway with out the waterpump turning and have your engine live.

Old Deis

Ya, wear your heavy gloves as was mentioned, the impact wrench will do it.

On the front bumper... I could use the center piece of rubber thats in the middle, 2' wide x 24' long, from the passenger side. Mine is non existent so even an ugly one would be an improvement. I am wanting to restore my black cloth seats and could use some of the material to take to the upholstery shop (Rapps in Paulsbo), to patch a couple of panels. Something off an otherwise trashed seat. Thanks Steve fidlersg@olympus.net

I really should have added "use a M8 allen wrench inserted into the end of the alternator pulley shaft" then you can get plenty of counterholding force right where you need it.

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'82 300SD - 361K mi - "Blue"

"Good judgement comes from experience. Experience comes from bad judgement."

listen, look, .........and duck.