Does anyone know how difficult it is to remove the pulley wheel thats connected to the alternator? I think the bearings are shot and will confirm this tommorow before ordering from the stealership.It appears to have a clutch type thing inside it ,and i have noticed a rust coloured dust on it and also on the plastic engine cover,it also appears noisy and i will remove the belt tommorow and confirm this.Thanks for any info or tips.

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2004 2.8 crd Limited

Hello M8, it's not so difficult but you need the right tools.

Firs of, if I remember correctly there is no real bearing inside the pulley. There is a sort of autobrake system in it so it can freewheel when not needed.

Take of the pulley plastic cover plate.

There are two types, one with an internal hex and one with splines. Hopefuly you have the one with a hex.

Now on the alternator shaft there's also a hex. It's a 5/8 I believe, somewhere around key 10 in metric.

You need to hold that and then turn the pulley counterclockwise to loosen it. JEEP dealers have a special tool with a double hex to also grab the pulley internally. I ended up taking the whole alternator of my engine, take an angle grinder to it and then bashing it with a chissel and a hammer to brake pulley loose while a socket held the axle.



Since I already destroyed the old one I took it apart completely to know what was inside, the screachy noise you here is just from the 'brake' dust that has no where to go. The brake pad was still in good shape. Blew 150€ on the part. Next time it gets noisy I'll try drilling 2 holes in the front right next to the big hex and blow it out with compressed air. The plastic cover should be enough protection to keep ( rain -) water etc out.

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Cherokee 2,5 CRD: sold - Wrangler TJ 2.5: gone - Touareg V10 TDI: new toy

Solo Liberty en Español: Jeepliberty.es

Thanks Tony most helpful mate.

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2004 2.8 crd Limited

Hi Tony what part did you attack with the angle grinder? And were on the alternator did you hold the shaft to help undoing it.Iv'e not taken it off yet will do that when parts arrive but i have pinpointed the pulley as the problem today.Also i dont seem to have a plastic cover on mine.

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2004 2.8 crd Limited

Hello Jimmy, sorry to reply so late but I didn't see your post until today, things sure move fast and get LOST real quick.

I grided out a small part of the pulley's outside rim so my chissel had somewhere to fit. Then I banged it with a hammer.

Sorry don't know how to discribe it better. I think you get the picture. I held the alternator's axle with a socket to keep it from turning.



If you take of the alternator and look in the centre hole of the pulley you see the axle and the small hex. If you see only splines take it to a dealer so they can take it of for you. You need the special tool.

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Cherokee 2,5 CRD: sold - Wrangler TJ 2.5: gone - Touareg V10 TDI: new toy

Solo Liberty en Español: Jeepliberty.es

I have swapped bearings out of many Delco and Bosch alternators. The hex in the rotor shaft is often not strong enough to remove the nut. Remove the alternator from the engine, carefully split the back side of the housing and stator. The slip ring brushes will try to fly out and get lost. Look for a place in the brush holder to place a pin or wire that can be pulled out when you need to put the alternator back together. Then wrap a rag around the rotor and use the impact wrench to remove the nut.
If the brushes are worn out, look for generic replacements if you can't buy the originals. I have use power tool brushes from hardware stores in a pinch. If the brushes are too big, they can be sanded down to size.
Sometimes the bearings are odd sizes and can not be purchased from bearing suppliers. If you run into this problem, let me know and I will show you a trick to increase the bearing ID.

Regards,

Steve

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle

Thanks for that comment Steve but JEEP decided to fit a pulley with no nut. The thread is inside the pulley/freewheel combo. And there lies Jimmy's problem, the bearings on the alternator are just fine, the stupid pulley squicks.

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Cherokee 2,5 CRD: sold - Wrangler TJ 2.5: gone - Touareg V10 TDI: new toy

Solo Liberty en Español: Jeepliberty.es

Tony: Sounds crazy like they are smoking hemp rope. Here in the states air impact wrenches are cheap at discount tool stores or at Pawn Shops. Mine are old Chicago Pneumatic that I have rebuilt more than once. Swap the component instead of fix it is an attitude that started in Detroit and spread to Germany and then to other parts of the world. If you ever get one off and apart, take photos so we can all see.


Steve

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2006 Pearl Green CRD
Magnaflow 2 1/2" Cat Back
KJ Extra Leg Room Brackets, Carter Lift Pump, V6 Airbox, ORM
Fuel cooler, Oil Separator, Progard 7
Gauges EGT Boost Trans Temp Oil Pres, Michelin LXT AT2 245 70 R16
7,000# Draw Tight hitch, PML EX Deep Trans Pan
Centrifuge, SunCoast, Transgo, RAM TCM, InMotion Stage 2
Wife's 99 TDI VW Beetle