 So THAT'S why I keep throwing belts, How does a break like this even happen? |
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| iankarr |
 Jun 18 2017, 10:13 AM
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#1
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The wrencher formerly known as Cuddy_K  Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region 
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Hi guys,
After I threw my second alternator belt I decided to investigate a bit deeper and discovered that the pulley is cracked. See pic. Is it practical/possible to replace just the pulley with the alt in the car? I guess I'd need a point of leverage to hold the pulley still while breaking the nut. Or...is it better to bite the bullet and remove the alternator and repair on the bench? I suppose the third option would be to replace the entire alternator "while I'm in there". Thoughts/advice? Thanks! Ian  |
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Replies(1 - 19)
| PanelBilly |
Jun 18 2017, 10:23 AM
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#2
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914 Guru Group: Members Posts: 5,796 Joined: 23-July 06 From: Kent, Wa Member No.: 6,488 Region Association: Pacific Northwest
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Pull I out. It's not that hard to do. The pulpy needs to be pressed on straight so there's no wobble or you'll just throw the belt again.
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| iankarr |
Jun 18 2017, 11:38 AM
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#3
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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Thanks Billy. Figured it would be easier out of the car. Does the pulley need to be pressed on? I thought it was just held by a nut and woodruff key...
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| TheCabinetmaker |
Jun 18 2017, 12:09 PM
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#4
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I drive my car everyday Group: Members Posts: 8,300 Joined: 8-May 03 From: Tulsa, Ok. Member No.: 666 |
Yes. Pulley has a keeway. Never pressed one on and never had a problem throwing belts. The nut will pull it on straight
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| euro911 |
Jun 18 2017, 12:10 PM
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#5
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Retired & living the dream. God help me if I wake up! Group: Members Posts: 8,845 Joined: 2-December 06 From: So.Cal. & No.AZ (USA) Member No.: 7,300 Region Association: Southern California
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Wow, never seen that happen (IMG:style_emoticons/default/blink.gif)
Most new or rebuilt alternators don't come with a pulley, so you'll need to source one somewhere. |
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| 914Sixer |
Jun 18 2017, 12:41 PM
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#6
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914 Guru Group: Members Posts: 8,863 Joined: 17-January 05 From: San Angelo Texas Member No.: 3,457 Region Association: Southwest Region
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Guy over on theSamba is selling NOS one's for $35. Look under 411/412 parts.
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| iankarr |
Jun 18 2017, 01:32 PM
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#7
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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Thanks for the tip! Just emailed him....
Here's the link in case anyone else needs... https://www.thesamba.com/vw/classifieds/det....php?id=1717422 |
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| Spoke |
Jun 18 2017, 01:57 PM
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#8
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Jerry Group: Members Posts: 6,972 Joined: 29-October 04 From: Allentown, PA Member No.: 3,031 Region Association: None
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It looks like the pulley was cracked for some time. Notice the discoloration and rust where it broke.
Attached image(s) 
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| iankarr |
Jun 18 2017, 02:07 PM
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#9
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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good eye. looks like it started at the edge. Prob a combination of harmonics and stress caused it to spread and give way. I'm pretty sure my car wasn't driven much for a long time before I bought it in March of this year (just maintained and kept in a dry place). Now that it's back out on the road regularly the weak points are showing up. I hope that's the last of 'em...
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| porschetub |
Jun 18 2017, 03:30 PM
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#10
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Advanced Member Group: Members Posts: 4,696 Joined: 25-July 15 From: New Zealand Member No.: 18,995 Region Association: None |
QUOTE(cuddyk @ Jun 19 2017, 08:07 AM)  good eye. looks like it started at the edge. Prob a combination of harmonics and stress caused it to spread and give way. I'm pretty sure my car wasn't driven much for a long time before I bought it in March of this year (just maintained and kept in a dry place). Now that it's back out on the road regularly the weak points are showing up. I hope that's the last of 'em... That belt is the wrong section,looks to have stressed a weak pulley,never seen one break like that,looks rather thin @ the point where it broke (IMG:style_emoticons/default/sad.gif) |
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| rgalla9146 |
Jun 18 2017, 05:19 PM
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#11
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Advanced Member Group: Members Posts: 4,544 Joined: 23-November 05 From: Paramus NJ Member No.: 5,176 Region Association: None
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The sight line to do the pulley in the car is terrible.
To remove the alternator is even more terrible. Get a very big pair of channellocks to hold the pulley. Or, a large screwdriver with a square shaft can used in the notches of the pulley to act as a stop. First step is to remove the engine lid. Second, make appt. with chiropractor Attached image(s) 
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| ChrisFoley |
Jun 18 2017, 05:27 PM
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#12
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I am Tangerine Racing Group: Members Posts: 7,907 Joined: 29-January 03 From: Bolton, CT Member No.: 209 Region Association: None
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QUOTE(porschetub @ Jun 18 2017, 05:30 PM) That belt is the wrong section (IMG:style_emoticons/default/agree.gif) It sits too high in the pulley. |
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| iankarr |
Jun 18 2017, 06:19 PM
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#13
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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The belt just ended up there when I was feeling around to see what was up. Thanks for the tip Rory! I'll start taking Advil now....
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| euro911 |
Jun 18 2017, 07:44 PM
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#14
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Retired & living the dream. God help me if I wake up! Group: Members Posts: 8,845 Joined: 2-December 06 From: So.Cal. & No.AZ (USA) Member No.: 7,300 Region Association: Southern California
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QUOTE(rgalla9146 @ Jun 18 2017, 04:19 PM) ... It looks to have broken in between two of the notches if I'm seeing it correctly (IMG:style_emoticons/default/confused24.gif) (one of the notches is circled at 6:30 the other is at 2:30)Get a very big pair of channel-locks to hold the pulley. Or, a large screwdriver with a square shaft can used in the notches of the pulley to act as a stop. ... (IMG:http://www.914world.com/bbs2/uploads/post-3031-1497815826.jpg) |
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| Porschef |
Jun 19 2017, 05:48 AM
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#15
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How you doin' Group: Members Posts: 2,165 Joined: 7-September 10 From: LawnGuyland Member No.: 12,152 Region Association: North East States
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Ian, I did mine the weekend you showed up at Mort's; it's no fun. I had the advantage of having the heat exchanger off, which provides as much access as possible.
Get it upon your lift and have at it, send the unit out for a refresh so you won't need to go back in that dark hole again... (IMG:style_emoticons/default/dry.gif) |
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| McMark |
Jun 19 2017, 08:27 AM
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#16
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914 Freak! Group: Retired Admin Posts: 20,179 Joined: 13-March 03 From: Grand Rapids, MI Member No.: 419 Region Association: None |
It's not uncommon for the pulley to be stuck on the shaft. If you can replace the pulley in the car, count yourself lucky. But if it sticks, just stop and pull the entire alternator.
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| iankarr |
Jun 19 2017, 11:26 AM
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#17
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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Thanks guys. Gonna try to take off the short tin around the alternator and hopefully replace the pulley in the car. Wish me luck!
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| iankarr |
Jul 16 2017, 06:34 PM
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#18
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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Ok. Mission accomplished.
Because there isn't enough space between the firewall and the alternator to fit an impact wrench on the nut, I ended up just biting the bullet and removing the alternator. Really not too bad. Here's what I did and few pics if anyone else finds themselves in this situation. – First I removed the short piece of tin under the alternator (several cheese heads). I also needed to loosen the heater blower motor to get the piece out. – Next I took the left J-tube and the ducting out to gain access to the bottom alternator pivot bolt nut. Then removed the cheeseheads and 10mm bolt holding the front alternator plate. – Unplugged the alternator harness from the board, removed the eye terminal from the starter and pulled the grommet out of the tin. Disconnected the cooling boot. The alternator came out pretty easily. Check out the damaged pulley. Pretty crazy. Once I had it off I noticed that there were two other stress cracks on it. Could these be from age? Or some other stressor? Anyway...I'm going to try one of the Contitech Belts McMark, recommends and finally get back on the road. Thanks for the help!        |
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| iankarr |
Jul 19 2017, 09:19 PM
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#19
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The wrencher formerly known as Cuddy_K Group: Members Posts: 2,471 Joined: 22-May 15 From: Heber City, UT Member No.: 18,749 Region Association: Intermountain Region
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Put one of the conti-tech 10 X 965 belts in. Perfect fit, just as mcmark said....
First, on the old pulley...  And in the car...  |
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| euro911 |
Jul 20 2017, 01:59 AM
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#20
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Retired & living the dream. God help me if I wake up! Group: Members Posts: 8,845 Joined: 2-December 06 From: So.Cal. & No.AZ (USA) Member No.: 7,300 Region Association: Southern California
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