Alternator alignment issues - which part would you adjust?

[bull]

So I finally found what apparently is the electrical unicorn: a 78 amp single pulley square back alternator. Everything else I've found with a single pulley is 60 amp. However, under the heading "nothing can be easy" I put the alt it in its spot and found that it is misaligned, as in too far toward the front, for the belt to line up straight. I can do a bunch of washer/spacer tricks to move it back enough or could I possibly cut about 3/16" off the back of the pulley?

I was planning on removing the pulley anyway to have it powder coated black like the rest of the pulleys so this would be the time to chuck it up in a lathe and remove some material off the back. So the question is, are the alt shafts tapered or just a close tolerance press fit? If I take some depth off the back of the pulley will I be able to press it back down to its proper spot?

You can see below I have a lot of space between the back of the pulley and the front of the alt. Right now it looks pretty close to being aligned with a pair of 1/8 washers behind the bracket.

[FLG]

Curtis..why not paint the washers black or leave em...hardly noticable. But if your like me youll be mad knowing its there.

[bull]

What I'll probably do is get a puller and remove the pulley first and measure the ID on one side and then the other. If I get the same measurement I'll know it's not tapered and have a machinist cut 3/16" off the back before I powder coat it. I just don't like messing with washers and funky spacers if I don't have to. It looks dumb and then when installing or replacing you have to deal two washers, the alternator, the mounting bolt and all the tube spacers at the same time.

[elacruze]

That's exactly the alt. I found 'accidentally'. Mine came from a '86 Dakota, if I remember correctly. I had some alignment issues too- I ended up using some very nice 3/8" spacers available from ACE Hardware-they come in 1/8" and from there up in 1/4" to 1" lengths. Avoids the stacked washer syndrome lol. My alt has no problem keeping up with charging duties, even driving around town, idling, with A/C, EFI, and power windows. I never see less than 13v on my gauge, even at night, with idle speed @ 850.

[Nacho-RT74]

don't you get problems with rear spacer fitting those washers ?

I never have seen before washers between the front of the alt and the top bracket to align . That will give you problems to fit rear spacer which is pretty much important to keep tight the alternator and save it from vibrations able to break the bolt ( BTDT )

don't you have a single pulley around to compare once you remove that one ?

maybe the pulley is able to go further back without need to cut

I'm more familiar with A/C setups, sorry

[bull]

don't you get problems with rear spacer fitting those washers ?

I never have seen before washers between the front of the alt and the top bracket to align . That will give you problems to fit rear spacer which is pretty much important to keep tight the alternator and save it from vibrations able to break the bolt ( BTDT )

Yes, but the silver spacer it came with in the middle has about 3/8"  of it sticking out the back (you can see it at the top of the first pic). If I remove that one or cut it flush with the alt, the rear spacer will almost fit. Unfortunately removing that spacer would cause issues too because the stock middle spacer isn't quite long enough to fill the gap.

don't you have a single pulley around to compare once you remove that one ?

No, that's part of my problem. My original alt was replaced at some point with an alt that has a double groove pulley so that's why I had spent so much time trying to find a 78 amp single groove pulley.

maybe the pulley is able to go further back without need to cut

The pulley that's on it now is fully seated onto the shaft.

[bull]

That's exactly the alt. I found 'accidentally'. Mine came from a '86 Dakota, if I remember correctly. I had some alignment issues too- I ended up using some very nice 3/8" spacers available from ACE Hardware-they come in 1/8" and from there up in 1/4" to 1" lengths. Avoids the stacked washer syndrome lol. My alt has no problem keeping up with charging duties, even driving around town, idling, with A/C, EFI, and power windows. I never see less than 13v on my gauge, even at night, with idle speed @ 850.

I'll have to check with Ace and see what they have but I'm glad to hear this alt should be adequate.

[Budnicks]

That's exactly the alt. I found 'accidentally'. Mine came from a '86 Dakota, if I remember correctly. I had some alignment issues too- I ended up using some very nice 3/8" spacers available from ACE Hardware-they come in 1/8" and from there up in 1/4" to 1" lengths. Avoids the stacked washer syndrome lol. My alt has no problem keeping up with charging duties, even driving around town, idling, with A/C, EFI, and power windows. I never see less than 13v on my gauge, even at night, with idle speed @ 850.

I'll have to check with Ace and see what they have but I'm glad to hear this alt should be adequate.

Was the alt. pulley pressed on all the way ?, It kind of looks like it was sticking out too much, Just an observation...

[bull]

That's exactly the alt. I found 'accidentally'. Mine came from a '86 Dakota, if I remember correctly. I had some alignment issues too- I ended up using some very nice 3/8" spacers available from ACE Hardware-they come in 1/8" and from there up in 1/4" to 1" lengths. Avoids the stacked washer syndrome lol. My alt has no problem keeping up with charging duties, even driving around town, idling, with A/C, EFI, and power windows. I never see less than 13v on my gauge, even at night, with idle speed @ 850.

I'll have to check with Ace and see what they have but I'm glad to hear this alt should be adequate.

Was the alt. pulley pressed on all the way ?, It kind of looks like it was sticking out too much, Just an observation...

It does have that look when you view the space between the back of the pulley and the front of the alt. But if you look at the base of the gold metal (pulley base) you can see it's seated all the way down.

I borrowed a puller from Autozone tonight and after I remove it and take it to work (where my calipers are) I'll know more.

[Budnicks]

If you have a Orchard Supply & Hardware up there, they have Chrome plated spacers appr. 3/8" inner & appr. 1" outer diameters with 1/4"-1-1/2" & many other various lengths/sizes, I just ground a couple to fit a custom install, I did on one of mine, because of using an aftermarket 25.1 SFI cert. harmonic damper & 6 rib serpentine belt, that are much thicker & push the alternator belt alignment out like 3/8".... Good luck

[bull]

Neither of the Autozone pullers worked. I think I'm going to take this one back to the parts store, explain the problem and try trading it for another reman of the same kind and gamble that the next one might be right. If not I'll take that one to a shop and have them remove the pulley for me and then cut 3/16" of the back off, powder coat it or paint it and then have the shop reinstall it. I swear, this restoration has been a battle from start to finish. Well, if I were finished.

[Nacho-RT74]

I swear, this restoration has been a battle from start to finish.

you tell me!!!

[A383Wing]

got a pic of the front of the pulley?

Bryan

[bull]

got a pic of the front of the pulley?

Bryan

I can get one posted later. The problem is the space between the lip and the front of the pulley (the spot where you attach the puller) is not very deep on the new alt. It's identical to the old pulley in that spot other than the depth so you can't get a standard lock collar puller under the lip.

[bull]

Here's what I'm talking about. You can see that the new pulley has a lot less space to get a puller in there than the old one has.

[A383Wing]

yea..that's what I was thinking...you got the wrong pulley on there

Bryan

[elacruze]

yea..that's what I was thinking...you got the wrong pulley on there

Bryan

Mine is Dual-belt, but yellow like that.

[bull]

So where do I get the correct, single-belt pulley if this new one is wrong?

[A383Wing]

I probably have some here...but yer gonna have to get that one off, and then take alternator apart to press a new one on....

the place you got it from will not exchange it?

Bryan

[bull]

I probably have some here...but yer gonna have to get that one off, and then take alternator apart to press a new one on....

the place you got it from will not exchange it?

Bryan

Yea, they are but it takes a day for it to get there. I'm just hoping this one is an anomaly and the one that comes in will have a pulley that's right. If not I'll probably just tell them to keep it and I'll buy one of those 75 amp deals just like it from Mancini, assuming their pulley is right.

[A383Wing]

well, let me know if I need to dig through my pulley stash and see if I have the correct one....I'm gonna be out in the garage most of the weekend.....

Bryan

[Budnicks]

I have a dual chrome pulley that was a take of from my Powermaster 75amp Chrome alternator, I switched to serpentine 6 rib belt & aluminum pulleys....  If you need it...

[bull]

well, let me know if I need to dig through my pulley stash and see if I have the correct one....I'm gonna be out in the garage most of the weekend.....

Bryan

Ok. I have three maybes already so I'll let you know what I find.

[bull]

BTW, I went and got that second alt from the parts store just to see if I'd get lucky with the pulley and I did! Except it was bad luck.

[FLG]

I might have one as well...will check my parts stash and report back in a bit.

Well same luck, all ive got is a dual belt pulley alt.

[A383Wing]

I got a single pulley here...I can take a pic and measurements if ya want

Bryan

[A383Wing]

you still needing a pulley?

3" in diameter, 1-1/2" tall overall

Bryan

[bull]

  How much you want for it?

[A383Wing]

you can have it for mailing cost

Bryan

[bull]

you can have it for mailing cost

Bryan

You sure? That's very cool! Thanks, I'll PM my address. Maybe I'll send you a little something for your trouble anyway.