I bought a new FD alternator from the parts store, and am trying to fit a pulley onto it. I don't remember who I bought the pulley from, but it was supposed to fit right on without any modifications. It has a center big enough for the shaft of the alternator to go through, but when the bolt is tightened down, the back edge of the pulley is rubbing on the housing. So, I went to the hardware store and picked up a washer that was as close to fit as I could get it. With my dremel, I am cutting it down to fit inside the little area. I am hoping this will push the pulley out far enough so that it will not rub. Has anyone else had this problem? The pulley I bought has a rotor on the front. I don't remember who I bought it from, anyone think that sounds familiar. I thought I bought it from bonzai.

If this is a common problem, am I going about it right? I am hoping that after pushing the pulley up slightly, I will be able to get enough threads on the nut.

I might end up taking it down to a machine shop and having them machine the back slightly so that it will fit.

Thanks for any information!

 

Be careful that the spacing of the pulley is exactly the same as the spacing of a S4/S5 alternator pulley or your belt will be offcenter. I could see it causing vibrations if the difference is bad enough.

 

Yes, this is a common problem. Mine came w/ a spacer behind the pulley. If I were at home, I'd pull it off and measure the thickness for ya, but I'll be here for another 16 hours

 

I've got the same pulley on my FD alt. I believe all I did was ground down the lip on the alternator. As I remember it, with a spacer the pulleys were off center.

 

I have an S4, not sure if this comes into play or not. I also have a 6 rib serpentine pulley, but used the same spacer before I went with the serpentine setup. On the S4, you need to use a spacer on the pivot bolt, as the ears are a different width on the alt than on the alt mount. But then I am probably just confusing the crap out of you

 

Thanks for the quick responses.

I don't think mine came with a spacer, but I will check again. Does anyone recognize the pulley with a rotor on the front as being one from bonzai? Very nice piece. Maybe I can write them and see how much it would cost to have a spacer sent.


Or, I could grind down the lip on the alternator. Trying to avoid doing anything to the alternator seeing as how it is brand new. Might not be too bad if grinding down the lip that sits around the shaft. If, that is all that needs to be ground. Anymore information, like if that would actually work, would be great!

Thanks a lot guys! Can't wait to get this in my car.

 

Well, i am a little leery about grinding the lip on the alternator. Anyone know if this will work or not? Or a way to check?

I am on vacation right now away from my car, but when I get back i will be doing what I can to get the alternator and my new starter in.

Thanks again guys!