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OK, so its not exactly electrical. But it is on the alternator.

I'm trying to remove my EJ20G's alternator pulley. I've purchased a pulley underdrive kit which included a billet replacement and I'd like the shiny bit on my engine!

At the moment I'm trying to remove it using a 24mm socket on a breaker bar, holding the pulley with a piece of cut 5pk belt and a Boa wrench. I've tried using the full belt with the tensioner tightened right up, but the pulley still slips there.

If you have axcess to a rattle gun that would be your best bet tim, you need that sharp loosening motion.


Mike.

I have a rattle gun but a really weak compressor. I've heard the cheap way out with compressors (for home use) is to get two $99 Bunnings ones and tee them together, gives enough flow for big air tools apparently.

Either that or I get a power bar I suppose.

I have only seen these removed by taking the alternator apart and putting it in a vice. They are done up VERY tight... im not surprised u can't get it off.

Dave

The way I've removed mine before was to tension the belt as tight as i could, then got a QuickGrip (those clamps where you squeeze the handle to tighten it) and placed that either side of the Alternator pulley to further tension the belt.

I then got a breaker bar, followed by a large piece of timber. Then proceeded to belt the living crap out of the breaker bar until the bolt came loose!

A small metal band oil filter wrench around the pully somtimes works.....that or using big multi grips and a bit of ragg on the pully will work with a real good rattle gun.

The FSM procedure does state to do like somone else in the post mentioned.... disassemble the rear section of the alt and hold the armature in a vice(soft jaw) then use a breaker bar

Or you could do what I do somtimes in this sort of situation.....take your alt, boa wrench and socket down to the local tyre shop.... ask nicely to use their rattle gun for 30 secs and they usually let you have a wack on it.

OS

Thanks guys.

I tried to take my alternator apart the other day (I have a vice so this is the easiest option I suppose). I took all the nuts & bolts off the housing, but it wasn't going to come apart at all. None of my manuals have a teardown guide, can anyone point me in the right direction?

...they are just fuggen hard to get apart ! If your only swapping the pully over and the alt works fine now(may not after !) I`d be finding a way to get it off that doesn`t involve teardown.

Have you tried holding the pully as best you can and smacking a spanner with a gimpy ?.....better rattle gun.

Disassemble procedure for ;

Hitachi

remove bolts/srews thru body
tap off front alloy cover and remove with shaft assay.
Then put it in a vice !

Mitsubishi

Involves heating rear cover bearing area to ~60 degrees ....
Use 2 screwdrivers to pry centre section and front cover apart and remove assay
Vice.

OS

I've got a fairly big compressor and rattle gun if you want to have a bash at it, bit of a drive up the freeway tho. Reid Highway exit for me.

Just checked, I have the Hitachi unit. I'll tap a bit harder when I next get at it.