Pulley Diameters
All belts and accessories are now lined up except for the alternator. I think if we replace the single alternator pulley with a dual pulley, the last piece of the puzzle will fall in place....
From doing some research, the pulley change over is not a piece of cake :BangHead:
We have a puller to get the pulley off, but not sure about installing the new one. Words of advice??
Changing a mopar alternator pulley isn't difficult or technical but does require the special pulley puller.
Instructions:
removal;
Remove alternator from engine.
Remove 2 brush holders being careful not to break the brittle castings.
Remove the 4 case cover screws.
Carefully work the front cover loose from the stator about 1/4 inch, leave the stator solidly installed in the rear cover.
The Rotor and front cover will now lift straight out, nothing will go "sprang" or fall out on the floor.
Clamp the outside of the rotor in a soft jaw vise.
Install the puller onto the removal flange on the front of the pulley.
I use a 3/8 drive impact to power the puller due to the fast hammer action.
After about 1" of movement the pulley will pop off.
Installation;
Balance the rotor into the press on its rear bearing with the pulley end facing up.
Lightly oil the front shaft and the inside of the new pulley with any oil.
Balance the new pulley on the front shaft and press in place until it stops solidly on the bearing.
Reassemble the alternator in reverse order.
If the bearing needs replacement (don't they always?) carry on from where removal left off.
Removal:
Looking into the back of the front cover in under the rotor you will see a three sided black spring steel retainer plate covering the back of the front bearing. Use a flat screwdriver to pry the three corners off from their little ledges on the front cover.
Now sit on a soft chair and lay the front case edges over the top of your thighs with the rotor between your legs.
Rap sharply on the front end of the shaft repeatedly with a bronze or plastic hammer until the rotor and bearing are dislodged from the front case, about 3/8 inch. Use caution to catch the rotor so that it does not fall on the floor - the reason for the soft chair.
Remove the old bearing using the same puller as you did to remove the pulley.
Installation:
Clean out the bearing recess in the front case and apply a bit of oil to it and the new bearing inside and out.
Lay the front case on a hard surface and drive the new bearing into the recess much as you would install a wheel bearing seal.
Once the bearing is fully seated the hammer will bounce.
Reinstall the three cornered black retaining clip.
Set the rotor in the press front end up.
Balance the case on the front of the shaft and set the pulley on top of the front of the bearing.
Press into place until fully seated.
Reassemble the alternator reverse order.
The entire job takes about 45 minutes.
Steve
