Mrs 3Ltr stopped today

[solarman216]

Yes called out to the 3lt today amongst all else I had to do, popped the bonnet and did not like the angle of the serpentine belt, got the torch out and seems the alternator pulley was not where it should be, I was a bit dubious about starting it first, not wanting it to come off and do more damage but looking at the belt realised all the time the belt is tight it would keep it in line roughly, so jump started it and sent the Mrs on her way home.

So can somebody tell me why oh why these ridiculous free wheel pulleys are used? a free wheel will not be going back I can assure you, Rick

 

[panelbeater]

my alt went when away with my cvan and i got one in chesterfield.i had not seen one like it but easy to take off and exchanged it for replacement alt which came with new pully fitted.i think its to do with when starting it breake the sudden load on alt,could be wrong though.so you might need a new alt.

 

[Banshee]

Nightmare Rick!!!

Glad it wasn't terminal, some pics would be good when you come to do the job.

I was stripping a 3.0 ZD30 Patrol engine down for parts last night that I picked up from London a while ago when I picked up the Y61 axles and Front Winch Bumper for my Patrol.

I've been in touch with a lad who seems to be active more over on the Facebook group side of things and he asked me for a Power Steering Pump for his Terrano ZD30 and the part was identical physically (or so we thought)

After some research, it appears that the Patrol ZD30 pump is actually higher output, which you'd kind of expect really with all the extra weight compared to a Terrano.

This gives me a lot to think about if I do come to transplant a ZD30 into my Y61. It's not looking good with my head that's gone away for repair as they still haven't managed to get my broken glow plugs out :doh

So me and Flying Torquewrench have stuffed it

 

[solarman216]

OK so this is the problem with the alternator, this is where the pulley should be

 

[solarman216]

And this is where it was when I saw it on the car, but after starting it the belt pulled it back but the alternator was barely charging due to slip

 

[solarman216]

Shim inserted to hold the brushes

 

[solarman216]

Com is in good order

 

[solarman216]

The two bits

 

[solarman216]

Broke bearing

 

[solarman216]

Calliper on top part of shaft

 

[solarman216]

And bottom, not a clear pic but about 1mm smaller

 

[solarman216]

The mess from inside the pulley

 

[solarman216]

So stuck the armature on the lathe to make it parallel again

 

[solarman216]

Now all good again

 

[solarman216]

Now all I need to do is make a good fitting bush to fit between these two

 

[solarman216]

This is the stock that it will be made from, took some hunting down as I needed steel not cast, this is a roller from an old pipe bender, but not today, job for tomorrow, Rick

 

[panelbeater]

great set of picks rick,never seen inside one of the pulleys.

 

[Banshee]

Lovely stuff Rick!!!

Can't beat the old school tools

 

[solarman216]

Back on it today interspersing with directing tree surgeons, so this is boring the shaft hole aiming for 1Thou smaller than the shaft

 

[solarman216]

Bore done now the outside, had to do it in two halves as the bore would not quite go over the internal chuck jaws