Here is a good used alternator that was in my wife's car. The idiot electrician who installed it had dropped it and caused the pulley to be damaged but put it in the car anyway. The damaged Pulley caused the belt to be destroyed really fast. We got another alternator installed but this one is perfectly good except for the pulley. Here is how I removed the pulley.
A torx socket, 3/8inch Ratchet and a 24mm (or 15/16") spanner. An easy enough counterclockwise turn while holding the shaft with the Ratchet and the nut came loose. The nut unscrews and the
pulley slides out. Can't get any easier than that! Here you see the damaged area thanks to that jackarse auto electrician. In the future I will do the replacement of her alternator. Alternator Pulley Removal and Installation Instructions, What You Should KnowALTERNATOR PULLEY REMOVAL AND INSTALLATION INSTRUCTIONS, WHAT YOU SHOULD KNOWPulley Removal and Installation for Alternators with External and Internal fans: 1. To remove the alternator pulley, use a 1/2" Drive impact wrench to loosen the nut. 2. Alternator pulleys do not have a key and
should be a slip fit. sometime thread locking 3. Tighten the nut with an impact wrench until nut is tight (about 70 ft-lbs). NOTE : Many internal fan alternators use a self-locking nut that
do not use a separate lock washer.
 The exact process for alternator pulley removal can vary from one car to another, so it is important to examine each particular vehicle before beginning. It is sometimes possible to remove an alternator pulley while the alternator itself remains installed in the vehicle, though it usually is necessary to remove the unit first. There are two main types of alternator pulleys, which are either pressed on or secured by a nut and a lock washer. To remove a pressed-on pulley, a puller set is required. The tool needed for most other alternator pulley removal is a pneumatic or electric air gun. There are many reasons that an alternator pulley might need to be removed, though this operation is most commonly done when replacing the alternator. If the new pulley does not match the old one precisely, it could shred the belt or result in inadequate charging. Any time an alternator is replaced, the pulley on the new unit should be examined closely. The number of grooves on the new pulley should match the old one. They should also be of the same width, because a wider or thinner pulley can result in misalignment, which could either shred a belt or cause it to roll off. It also can be necessary to remove an alternator pulley if the old one has been damaged. In this case, it might be possible to perform the alternator pulley removal without uninstalling the alternator itself, though modern engine compartments rarely provide enough space. For this time-saving procedure to work, both the removal and installation processes must first be considered. The tools necessary to install an alternator pulley sometimes take up more space than those required to remove one. One common method of securing an alternator pulley is with a nut and lock washer. The easiest way to perform an alternator pulley removal in this case is usually with an electric or pneumatic air gun that is capable of producing a large amount of torque. The pulley will tend to turn along with the nut, so the tool that is used must have a great deal of initial torque to immediately break the nut loose. Securing the new pulley can be more difficult, because using an air gun in that application makes it difficult to judge whether sufficient tightening force has been applied. If the shaft is keyed with a hex pattern, it might be possible to secure it from turning with a hex bit so that the nut can be tightened with a regular wrench. Other alternator pulleys are pressed on, in which case a special puller is required. The alternator pulley removal process in this case typically involves placing the specialized puller on the alternator and then turning it until the pulley comes off. This same tool can then be reversed to press on a new pulley and can often be used with power steering pulleys as well. If a regular puller is used instead of the correct tool, it typically will cause damage instead of easily removing the pulley. Can you replace just the pulley on an alternator?In many cases it is possible to remove and install the overrunning alternator pulley while the alternator is still on the engine. The plastic protective cap cannot be re-used after it has been removed from the pulley. A replacement cap is supplied with the new part.
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How to remove pulley from alternator
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