sorry 'bout the foul mouth but i just used a clone of the tool shown in the fsm and bent the crap out of my brand new tuff stuff 100 amp alt pulley. my current alt has a 3 inch pulley that i want to use instead of the supplied 2 3/4 'cause of my 3.91's. the actual part where the belt rides is fine but the thick steel lip that the puller grabs is now fubar... what gives? any tips or tricks? thanks in advance. .....ps... grrrr i'm mad.

Still no reason for the language. The pulley would not have made that much difference. It wouldn't have changed the charging rate.

we need pics! (pulley/tool)

best way is to take the alt apart and press the pully off,then press the new one on and put it back together

pressing the pully on and the alt together can mess it up the back bearing



no biggie on the pully size and rpm

yes you need to split the case when pressing the new one on (as you need to support the rear of the shaft) but not needed when pulling the old one off as your doing your work on the front side but moot point as the case does need to be split. Still wondering what puller was used to try & get it off

pulley

tool and fsm. and so sorry if i offended with my edited cursing.

that looks like the puller i use on the bath tub handles when plumbing

I didnt hear you say a thing,i read it so its all good to me

I would try a bearing spliter and press

thanks scatch'n, unfortunatly i don't have a splitter but it may be worth the investment, at this point from what everyone said i think i'll just run the 2 3/4" pulley. but if you look at the fsm picture under the tool. they are the same i'm just pissed i fudged a brand new shiny part do you think i'll be ok running the pulley like that?

the bent flange wont hurt a thing. And that alt, couldn't care less what gear your running.

other than looks its still good and still shinny

yea I would run it and not worry about that pully

as far as juice,i uped mine to a mini alt on my 440 in the sig pic

it was a bolt on,,double pully,external regulated,120 amps,smaller/lighter

yea thats the correct puller/i was just sayng it looked like the cheapy one for plumbing I have handles

This puller works and it goes on sale all the time for 50% off.

Pulley Remover and Installer Set

thanks i will look into that tool. i did scramble the letters in my title( which i have now changed) geez, I'm just venting/ kidding around, my apologies to all that found my title offensive.

The problem is that your pulley removal tool is a piece of junk. I have one just like it and have had similar results.

Pulling it is easy. Pressing it back on is a pain. One more reason to switch over to a modern alternator like the Denso. Not only do the work a lot better, they are easier to work on.

thats great news after i just recieved my new $150 cdn tuff stuff 100 amp alt....jk

Go to Advanced or Auto Zone.They have the pullers in their loaner tools.Looks like 2 halves that go around the outer flange.There is a sleeve that fits over them and a threaded bolt that goes into a big flat piece.they are easy to pull.Ive done hundreds at work.As said he alt needs to be split to press on although I have pressed a few on without spliting them.Rocky

I modified the puller screw in the kit I bought. The original screw had a tendency of cutting threads into the inside of the puller if you weren't paying attention to it's location.
I just chucked it up in my drill press and took a file to it.

Original Miller tool.

To install I use a 100 watt light bulb. Just put the new pulley directly on the lit bulb for 15-20 minuets. This should evenly heat it up so that the hole is large enough to slide on to the shaft of the alternator. On larger things that need a shrink fit I use a oven to get it expanded. There should be about .002" interference between the shaft and the pulley if not it will slip on the shaft. Not all alternators have the same shaft/pulley size.

i see the light,thats a good idea

like putting the screw/press in upper/lower ball joints on my 85 truck,stick them in the freezer overnight to shrink them some

ever been burned by a ruff service 100 watt bulb in a hand held shop light with metal shroud thats been on for hrs?

i wont grab it like that no more either

bet it would work on a crank damper also

Problem with the Miller tool is finding one.The kit is a loaner from Advanced Auto Zone.How many pulleys will you change at home.Now if you can find the Miller cheap thats a different story.Rocky

Dry Ice on the shaft to shrink it helps too,
along with gentle heat like a light bulb on the pulley.

Many grocery store chains sell Dry Ice and it is cheap, typically $7 per pound at Publix stores in Florida, for example.

If you can't find Dry Ice
these 'Freeze It' sprays are helpful too

http://www.crcindustries.com/ei/content/pst.aspx?PID=Panel2_3

http://www.amazon.com/CRC-05222-Freeze-Off-Super-Penetrant/dp/B000KKCQUW

http://www.loctitefreezeandrelease.com/instructions.htm

I'm using the exact tool (in red box) shown above. I'm reefing on this thing pretty hard, and it isn't budging.... How hard should it be?