Dealing with a failing alternator pulley can be a common headache for car owners. While professional tools exist, they can be costly and sometimes unnecessary. If you’re a DIY enthusiast, you’ll be pleased to know that you can effectively perform a car pulley removal right in your garage by crafting your own Car Pulley Removal Tool. This guide will walk you through the process of making and using a custom tool to remove your alternator pulley, saving you time and money.
To begin, you’ll need to acquire a specialized spline tool designed for alternator pulleys. A reliable source for this is Metalnerd.com:
Alt text: Metalnerd spline tool for car pulley removal, essential for DIY auto repair.
Alongside the spline tool, you’ll require a 10mm 12-point or triple square bit. This bit will be modified to fit snugly inside the spline tool, creating the core of your car pulley removal tool. These bits are widely available from various tool suppliers. You can often find sets of these bits at good tool stores, or individually from brands like Snap-On. A Lisle set (product number 60750) is also a popular and affordable option. A quick Google search for “lisle 60750” will point you to numerous retailers.
Alt text: 10mm 12-point bit, a component for crafting a custom car pulley removal tool.
The next crucial step involves modifying the 12-point bit. Using a bench grinder, carefully grind down the hexagonal base of the bit. The goal is to reduce its diameter so it fits perfectly inside the spline tool.
Alt text: Grinding a 12-point bit to customize it for car pulley removal tool assembly.
During the grinding process, ensure you don’t remove too much material. You need to retain a portion of the hex base to allow for wrench grip later on. Periodically test the fit of the modified bit inside the spline tool to achieve the correct size.
Alt text: Checking the modified 12-point bit’s fit within the spline tool for car pulley removal.
For precise grinding, having a spare alternator on hand can be beneficial. This allows you to take measurements and ensure the modified bit’s length is appropriate. Engine bay clearance can be tight, so shortening the bit might be necessary. In this example, approximately half an inch was removed from the bit’s end to ensure optimal fit.
Alt text: Shortened 12-point bit, customized length for effective car pulley removal in confined spaces.
With your custom car pulley removal tool now assembled, you can proceed with removing the alternator pulley. Start by accessing the pulley area, which usually involves removing the side splash guard and the serpentine belt. After removing the protective plastic cap from the pulley using a screwdriver, you can insert your newly crafted tool.
Alt text: Accessing the alternator pulley after removing the dust cap, preparing for car pulley removal tool insertion.
To remove the pulley, you’ll need two wrenches: a 17mm wrench to turn the pulley and a 1/2″ wrench to hold the alternator shaft steady. Since you are holding the shaft and loosening the pulley, turn the 17mm wrench counter-clockwise, just as you would loosen a standard bolt. Utilizing the car’s frame rail to secure the 1/2″ wrench can provide leverage while you apply force to the 17mm wrench.
Alt text: Using a custom car pulley removal tool with wrenches to loosen the alternator pulley.
Installation is essentially the reverse of removal. For tightening, you can use the harmonic balancer to hold the 1/2″ wrench steady while turning the 17mm wrench clockwise to tighten the pulley.
Alt text: Tightening the alternator pulley using the custom car pulley removal tool and wrenches for installation.
Finally, remember to reinstall the dust cap on the new pulley. The entire pulley swap, including tool modification time, can be accomplished in about half an hour, potentially less if the splash guard is already removed.
This DIY approach to car pulley removal using a custom-made car pulley removal tool is a practical solution for home mechanics. It allows you to address common alternator pulley issues efficiently and affordably, ensuring your vehicle remains in top running condition.
