$7 Alternator Pulley Removal Tool

mrkake · **Posted:** Wed Jul 03, 2013 1:37 am

I bought a new OAD for my alternator because the old one was squealing. I didn’t realize when I bought it that I would need a factory tool to remove it. After staring at the problem for a while, I was struck with the idea that I could rig something that would work. Here’s my solution. I bought a “close quarters” ¼” drive 10mm socket on the internet for $5 (including shipping) and then bought a ½” threaded rod connector (which just happens to have an external hex of 17mm). The connector is large enough for a ¼” extension to fit through and then snap the socket on the end and voila! The connector fits perfectly in the pulley hex so you can hold it from turning and the socket has plenty of room to turn to remove the bolt holding it to the shaft. I don’t have pictures of it in action because I am waiting for a new tensioner and belt pulleys to arrive (I’m just doing the whole thing at once). I did carefully pop the cover on the pulley that’s on the vehicle and confirmed that this set up works. Just thought I would pass it along in case anyone else needs to do this. Pics below…

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03CDKJ · **Posted:** Wed Jul 03, 2013 9:35 am

Nice! Good find/invention! Thanks for posting it up..... :JEEPIN:

dirtmover · **Posted:** Wed Jul 03, 2013 12:39 pm

Nice improv. I wonder if there's sufficient "meat" on that threaded coupler to drill it open and fit a standard 10mm socket down there? It must be pretty close.

OTOH, the Lisle tool is not that expensive and can be used for our pulley as well as a few other styles.

racertracer · **Posted:** Wed Jul 03, 2013 7:59 pm

MrKake...... You da man.

Excellent work and you get a star.

Dennis MacGyver · **Posted:** Thu Jul 04, 2013 4:54 am

You may now add MacGyver to your name, you've earned it.

racertracer · **Posted:** Thu Jul 04, 2013 6:15 am

mrkake wrote:

I bought a “close quarters” ¼” drive 10mm socket on the internet for $5 (including shipping) and then bought a ½” threaded rod connector (which just happens to have an external hex of 17mm).

Can you tell us where you purchased the items from with part numbers?

ATXKJ · **Posted:** Thu Jul 04, 2013 10:19 am

racertracer wrote:

Can you tell us where you purchased the items from with part numbers?

Yes please.

Google seems to think you lucked out with a 17mm external which converts to 0.669in or a tad more than 21/64's

McMasters-Carr lists several 16mm external (coupling nuts)

although in this application 16mm might be close enough.

but if you found a 17mm - that would be best

the 1/4" stuff just looks like Craftsman.

mrkake · **Posted:** Thu Jul 04, 2013 12:05 pm

I got the socket from a web site that was offering free shipping that day but here's an example of another one: http://www.sears.com/mountain-1-4inch-d ... 502252507P. I had the 1/4" extension in my toolbox. The threaded rod coupling is for 1/2" threaded rod. It just so happens that the hex is 17mm. I bought this at Lowe's. I borrowed a 17mm box wrench from the tool section and walked around the hardware section sizing various things. My original thought was to just get some 17mm nuts and weld them together. I've used threaded rod a few times and remembered the couplings were like long hex nuts so I found them and the 1/2" size just happened to have the right external hex size. They are probably designed to use an 11/16" wrench. The 17mm was a very snug fit but perfect for what I was after. Hope that helps.

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dirtmover · **Posted:** Thu Jul 04, 2013 12:08 pm

ATXKJ wrote:

Google seems to think you lucked out with a 17mm external which converts to 0.669in or a tad more than 21/64's

You may have more luck going metric. 16mm and 17mm are both fairly standard sizes for M10 couplers

audiboy86 · **Posted:** Thu Jul 04, 2013 7:56 pm

All it takes is a 17mm Allen socket and a good impact wrench and you can get it off with a little penetrating oil. But still a great build and a great idea.

racertracer · **Posted:** Thu Jul 04, 2013 9:01 pm

Tech worthy material.

mrkake · **Posted:** Sat Aug 31, 2013 6:30 pm

I FINALLY got some time to replace my OAD this weekend. As promised here are some pics.

This is the part that I bought at Lowe's

The connector didn't fit the stock OAD so I had to grind off about 0.5mm from each face of the hex.

Here's the setup that I used.

And here you can see that it fits. The unaltered side fits the new Litens OAD (as shown in previous pics.

At first I thought that I would just be able to remove the belt and unbolt this puppy. :banghead:

Wow was I wrong! I had to remove the alternator, soak the bolt down with penetrating oil about 6 times over a 24 hour period before it would budge. Then I cracked the socket (luckily I had another that I found in an old toolbox that was collecting dust in the corner). Finally success. I have to be honest, this worked, but if I had it to do all over again I would seriously consider just buying a rebuilt alternator. Still, I saved about $70 so I'm happy.

$7 Alternator Pulley Removal Tool

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