Alternator Pulley Annihilation

[Rusty Nail]

I know this topic has been around for a while but this occurance was new to me.

 

I have had the stereotypical juddering of the PAS at idle for a while, and was just waiting for 'right time' to sort it out.

 

A week last Wednesday a squealing appeared from the engine bay at anything below 1700rpm so I took it as being the alternator belt tensioner bearing having failed from the abuse the aternator pulley seizure would have inflicted. I took this as a sign (seeing as I was going on holiday on the Sunday)and ordered a new tensioner, belt and alternator pulley from Frauds on the Thursday.

 

On the Friday lunchtime, the squealing was accompanied by the lovelly smell of burning rubber. I took this as being the tensioner bearing having seized and the belt rubbing.

 

After picking up the parts later that day and removing the tensioner, I compared it with the new item and found it to be in full working order and within the same tollerances as the new item.

 

The fault led firmly at the door of the alternator pulley. After removing the alternator it became obvious that the formally seized pully had completely self destructed internally. The burning smell was the pulley bearing end cover being melted by bits of red hot bearing being spat out. The squealing was from the bearing not being able to drive the alternator under load and also the pulley rubbing on the alternator housing.

 

I had to weld round both edges of the bearing end plate to enable me to clamp the pulley in the vice and undo the alternator spindle using the spline drive. Total reassembly was completed in about 10 minutes with the new belt fitted and the old tensioner.

 

All is quiet now and the tensioner much more stable.

 

An easy enough fix for just over