I put an FD alternator in my car. The thing works great except for one thing: It uses a serpentine pulley. So I tried drilling out my old FC alternator to fit the new FD alternator (The FD pulley shaft is 24mm and the FC is 22). Of course, this turned out to be a big mistake. After installing the alternator, it gave me 18 volts idle for thirty seconds before the pulley started smoking and the engine died. Of course, the pulley had siezed (The alternator still spins fine) and the belt burned up. So. Anyone got any reccomendations?

 

Can you explain this a bit more? Something isn't right here. And the FD alternator shaft is 17mm. I have one on my car.

Brad

 

Hmmm... it sounds like you put the pulley on with no spacer, so it rubs against the body of the alternator... is that the case?

Brad

 

Sorry, the nut is 24mm. Anyway, yes. It appears to be something like 16 mm (that's the size of the three washers I used.) I believe that very quickly, the nut screwed itself down onto the shaft, pushing my poorly machine-holed pulley down the shaft to the shell of the alternator, off the threaded part of the shaft, so that it scraped against it. What was your pulley solution?