My husband tried to install our new alternator today on our 95 cherokee. It is not an understatement to say that I thought he was going to light the Jeep on fire. It took an hour and a half of fiddling, checking the forums for tips, inventing new swear words, and sweating a little blood to get the old one out. So, of course the new one just dropped in like nothing. However, when he went to replace the serpentine belt, nothing he could do would make it fit. I know the PS pump was pivoted as far as possible, because you can hear it hit the end of it's slide. After conversing in calm civilized tones for a few minutes, I realized that he did not put the old pulley on the new alternator, even though the new Bosch alternator's pulley is about 3/16" bigger all the way around. I asked him why he didn't swap them, since the new one is obviously a different size, and he said "because I couldn't get the old one off". Hm. Anyway, I guess 2 questions: is there a way to make it work with the bigger pulley? His thinking is that the tensioner moved SO much that 3/16" shouldn't make that much difference. And, if you have
to replace the pulley, how do you break that nut on the pulley shaft when the stupid pulley spins? Is there a way to brake the pulley while you use wrench? Will an impact wrench do the trick? Ok, three questions - Is there any way to change that pulley out without taking the whole flippin' thing apart again?
Thanks for your help. Your advice, and several beers for both of us tonight, may save our marriage