I just got my new alternator from RockAuto.com and it came with the larger 6 groove pulley. My old alternator has the 5 slot pulley (I didn't have an option between 5S and 6S when ordering online). I have tried in vain to get the pulleys off so I can swap them but neither will budge.

Is there an easy way to get them off? Do I need some sort of special tool or jig? Can I just use the current pulley and make sure the "extra" slot is on the outside? I called a couple of local parts stores and they said they wouldn't be able to get them off either.

Thanks for any guidance you can offer!

I've messed around trying to get the stupid pulley off GM alternators... I've bent a few cooling fins trying to hold the shaft still.

I've found the best solution is to use an impact gun set at the lowest setting to remove the pulley nut.. The sudden shock of the gun usually breaks the nut free. The nut comes off almost instantly.

quote Originally posted by Poncho Jim: I've found the best solution is to use an impact gun set at the lowest setting to remove the pulley nut.. The sudden shock of the gun usually breaks the nut free. The nut comes off almost instantly.

I've bought a few Grand Am alternators from Advance. All had 4 groove instead of the required 5 groove pullies. That's how they swapped them out.

quote Originally posted by fierofool: I've bought a few Grand Am alternators from Advance. All had 4 groove instead of the required 5 groove pullies. That's how they swapped them out.

Same thing our guys do, they keep a cheapo electric impact hammer out back. Works great for that purpose.

I ran a 6 groove for years on a 5 groove belt, no problems... However, yea, impact is the only way to go. Anything you use to try to hold the shaft still will invariably destroy something. You might get away with a rubber strap wrench on the pulley, but sometimes the nut is too tight for a strap wrench.

Same here when I worked at Autozone. Impact wrench would spin the nut right off.

Thanks a bunch all.. I will try to pick up an impact wrench and see what I can do. For the time being I went ahead with the install and it seems to be OK - just wanted to see if I could get the engine running again..

Welcome back to our little corner of the world and to this forum. There are a bunch of us around you that can help you, should you need it, including one in Braselton. As VP of the Georgia Fiero Club, I'd like to take the opportunity to invite you to join us at next month's meeting. www.gafiero.org

If you can find no one to remove it, try going to the Advance in Winder and asking for John. That's where I purchased mine, and they always just held the fins with a gloved hand and hit it with an electric impact.

PS: Think I've seen your signature on a license plate.

quote Originally posted by Fierobsessed: I ran a 6 groove for years on a 5 groove belt, no problems... However, yea, impact is the only way to go.

I'll have to try that! I'm another one using the 6-groove pulley, but no problems yet.

Fierofool:

Hahahaha - yep I have my amateur radio call sign (KG4ONJ) on my Tundra tag. Thanks for the invite to the club meeting! I think that I'll be in Arizona for a conference during the April meeting but maybe I can make the one in May. And maybe my car will be in drivable condition by then too!

Thanks for the help and the heads up on the Advance in Winder - I tried the one on 53 in Chestnut Mountain and they wouldn't touch it. They said there was too much liability involved. Hmmmm..

I had the same thing happen when I was replacing the motor on my car 2 years ago, and putting new alternator as well. Well I didn't notice the wrong pulley until after I had taken my core back. Went back to the store and they had already shipped my core out. I contacted the Alternator re-manufacturer and the express mailed me the correct one. They said the same alternator is used in a Jeep aplication (and they use a lot more than Fieros) and it uses a 6 groove pulley, so that is what they ship them all with.


Rich

Running the 6rib pulley will NOT hurt anything, it makes it easier if you ever do an engine swap honestly....