Alternator pulley repair

[Pigeon_Droppings2]

Recently replaced an alternator on a v70....the old one was an ebay jobbie that I fitted a few years back. The only issue with it is the free wheel pulley has siezed which was slowly destroying the aux belt (ultimately that would have destroyed the engine on a v70!)

So....I decided I might just swap the pulley but the tooling is non standard it seems so my regular tool set for pulley swaps doesn't fit.

Does anyone recognise the tooling or have a suggestion which doesn't involve an angle grinder.

Current tool is a Sealey SX400....maybe I just need to buy a different set....but which one!

The outer ring that holds the pulley is fine....it's the inner ring thats the issue as it isn't splines but looks like toothed!

 

[Ashley Burton]

Have a look at the Laser Tool offerings. Nothing is simple these days with all these stupid specialist tools

 

[Melvyn Best]

Photo isn’t too clear or it could be my eyes but have a look at Ribe sockets they could be described as toothed? I’ve found using an air wrench to turn the rotor while holding the outer part seems to work best

 

[armalites]

I've got an alternator pulley removal set. I'll have a look as I've done one on one of my V70.

 

[Pigeon_Droppings2]

Cheers guys...I think it's definitely not a standard v70 key way....the alternator was an ebay jobbie so could be anythign I guess.

Here is another pic....it looks like it's expecting a tool that has angled ribs I think...never seen anything like it. Might be a grinder job!

 

[armalites]

This is very similar to the set I have and I just checked a V70 alternator and uses the third from the right in the box although my box is slightly different layout

https://www.ebay.co.uk/itm/18pc-Alt...505047?hash=item23c404cfd7:g:HHQAAOSwY~VdXVZL

 

[Pigeon_Droppings2]

Cheers armalites ....my set has an M10 which I tried but it doesnt go in because the splines are straight and I think this is expecting angled splines.

I think I may be looking at plan B (grinder )....not the end of the world if I destroy it. I suspect they wouldnt give me my surcharge back anyway if its not a volvo alternator to begin with.

Looks like it has teeth instead of the usual splines...all very odd

 

[armalites]

I suspect that was done that to stop someone taking the pulley off or someone has hammered the wrong fitting in there

 

[armalites]

One thing I found is there is a changeoever point where the alternators look exactly the same but one is a standard voltage based one and one is an ECU controlled. My 54 plate came with a spare alternator because the original was working but noisy. I pulled it out fitted the other and it didn't work. I then found I could just swap the regulator pack from one to the other and it all worked fine.

 

[Pigeon_Droppings2]

Yea they did make a change....this one had managed about 2 years and about 35k miles I think...pretty poor vs original but was ALOT cheaper.

I think I agree....they fitted the pulley and then maybe they tamper proofed the key way so the pulley couldn't be replaced. There might be a good reason....maybe to prevent someone (like me) trying to put a standard pulley on the end that maybe won't fit the shaft it uses perhaps.....or just to make me buy a new alternator when only the pulley freewheel is broken!

 

[premmington]

Cheers guys...I think it's definitely not a standard v70 key way....the alternator was an ebay jobbie so could be anythign I guess.

Here is another pic....it looks like it's expecting a tool that has angled ribs I think...never seen anything like it. Might be a grinder job!

Enter the grinder - "egg shell it"....

 

[Pigeon_Droppings2]

Yea thats what I'm thinking too.....I was wondering whether I can "just" cut the top and the main pulley will fall off?

Might be easier to stick it all in the metal band saw and see what happens

 

[premmington]

Yea thats what I'm thinking too.....I was wondering whether I can "just" cut the top and the main pulley will fall off?

Might be easier to stick it all in the metal band saw and see what happens

I have done hundreds of these - cut at diagonals across pulley - once you have got thru the outer pulley it will come off - the clutch mech will fall away - then attack the threaded bit.

The skill is not to go into the thread - just at the point you are getting near the thread the - the metal will change colour...

If you do mark the thread both sides - this is what loctite is for...

 

[Pigeon_Droppings2]

Cheers premmington....this is my first attempt at cutting one off. I was thinking the same...get the bulk of the pulley to fall away and then sort out the threaded bit. On Volvos these are left hand threaded so they tighten as they run....although if the freewheel is broken they have been known too unscrew the pulleys themselves....the aux belt then gets sucked into the cam belt and we all know how that goes.

Aux belt is 6 rib belt....1 rib had already been torn off....found it under the cam belt cover....that was lucky!

Only spotted the Aux belt/alternator when I was sorting out a dodgy diesel tank sender....these cars are too complicate!

 

[500e]

All cars are to complicated

 

[Pigeon_Droppings2]

Yea but volvos are just nuts.

Example....the diesel tank has a diesel lift pump (nothing unusual there).....but the tank is a saddle tank so there is also a sender unit on the other side of the tank and a pipe connecting across the tank so the lift pump can access the side of the tank opposite the pump.

Said pipe was floating around in the tank...interfered with the fuel level float and thats where my involvement begins. The pipe has to be clipped to the bottom of the sender which is spring loaded to keep the pipe at the bottom of the tank (took me 3 attempts to actually work that one out for myself!)!

Of course the tank had just been nicely topped up with diesel....which I found out when I unscrewed the sender (well the bloomin gauge was saying half full).

Doesn't sound too bad....but if you got as far as the diesel pump ....without disconnecting the battery then you better go get your laptop as you've just triggered a permanent dash warning.

Oh and whats that odd noise on tickover....ahhh the alternator is busted and 1/6th of the aux belt is missing....oh and I've only brought a basic tool set.

So back home...back to the garage ....to build the specialist tool to get the fuel sender out!

The joy of working on volvos....at least I got to use the Hyundai stick welder....worked pretty good too