Alternator OAD Pulley Replacement

[jaymz]

My overrunning alternator decoupler has been slinging grease for about a month and I’ve got a road trip planned for this w/e so I decided to finally replace it.

I can tell you all with great certainty that it can be changed without removing the alternator. I can also tell you with the same certainty that it’s easier to remove the alternator and change it on the bench.

That being said, here’s a few pics I snapped along the way:

The “stripe”.

Oil filter removal is necessary to install the removal tool. Hold the 19mm wrench and spin the 10mm clockwise toward the driver side. A MUCH longer wrench would have been helpful, but it’s MIA. Ratchet and socket could work if you have one that is slimmer than average.

It’s pretty much impossible to see what I’m doing here, but I used a pry bar to release tension on the belt to facilitate spinning the pulley off of the alternator shaft. This is the point that I decided I’m not saving significant time by “cheating”, and pulled the alternator to reinstall the OAD pulley.

Degreased OEM pulley. Posting in the event someone wants to attempt to purchase OEM parts at some point.

Replacement OAD Pulley.
Litens P/N 920080A. Don’t know why the “A” isn’t stamped on the part, but it’s the part number that I purchased.

Reassembly is obviously the same as disassembly, only in reverse. I would suggest belt replacement at the same time as you’re already knee deep into the stuff you need to remove anyway, but my local parts house was out of stock and my belt has plenty of life in it.

I’m into the job about an hour in time, and about $100 for the pulley and the tool. All in all not as much as a PITA as I was expecting.

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[RealSandman]

This is great. Thank you for sharing. Both of my Jeeps are doing the same, I have had the OAD pulley sitting on a shelf waiting for a free weekend to tackle it.
Which tool did you use here to remove the OAD?

I’m about to replace some ticking valve followers and might just take care of this at the same time.

 

[jaymz]

This is great. Thank you for sharing. Both of my Jeeps are doing the same, I have had the OAD pulley sitting on a shelf waiting for a free weekend to tackle it.
Which tool did you use here to remove the OAD?

I’m about to replace some ticking valve followers and might just take care of this at the same time.

I used the kit from Lisle. It can be had at AMAZON for about $30, though I paid less than that through my parts supplier.

Sorry for the late reply, I didn't see that there had been any responses until late last night.

 

[Lohkay]

Amazing! My alternator stopped working in June 2022 while I was 2h from any civilization. I managed to get back in town and the dealer changed the whole alternator. Later, I brought the "faulty" alternator to a local shop and they said the issue was the pulley but they couldn't find a replacement part.

Said alternator has been siting on a shelf since then, waiting for a pulley to be available. Now I can finally fix it and have a backup and/or sell it!

 

[AlgUSF]

So what breaks on these things? Seems like they really complicated an overly simple device that works quite well. In 30 years of car ownership I've only had a single alternator fail on me and it had like 250K mi on it.

 

[jaymz]

So what breaks on these things? Seems like they really complicated an overly simple device that works quite well. In 30 years of car ownership I've only had a single alternator fail on me and it had like 250K mi on it.

Mine wasn’t broken per se, it was just slinging all of the grease out of the bearing. It may have lasted for a hell of a long time. I really don’t know. It was just better for me to replace it before it failed out in the middle of nowhere.

 

[mwilk012]

So what breaks on these things? Seems like they really complicated an overly simple device that works quite well. In 30 years of car ownership I've only had a single alternator fail on me and it had like 250K mi on it.

It’s a one way bearing, fitted with seals and filled with grease.

 

[the5Lranch]

Jay how has the replacement OAD held up? Mine has been slinging grease for awhile now was just going to replace the whole unit but then I came across your thread.

 

[jaymz]

Jay how has the replacement OAD held up? Mine has been slinging grease for awhile now was just going to replace the whole unit but then I came across your thread.

Holding up great. No noise, no leaking.

 

[Nathan08t]

If I purchase this part do I need to grease it first or does it come pre-greased? Silly question I know but I'm having the same exact problem on my 18' with only 30K miles on it

 

[the5Lranch]

If I purchase this part do I need to grease it first or does it come pre-greased? Silly question I know but I'm having the same exact problem on my 18' with only 30K miles on it

It comes ready to install. Just did mine on my 18 (75kmiles) Can confirm that the easiest way to do it is to pull the alternator.

 

[Hokti]

My overrunning alternator decoupler has been slinging grease for about a month and I’ve got a road trip planned for this w/e so I decided to finally replace it.

I can tell you all with great certainty that it can be changed without removing the alternator. I can also tell you with the same certainty that it’s easier to remove the alternator and change it on the bench.

That being said, here’s a few pics I snapped along the way:

The “stripe”.

Oil filter removal is necessary to install the removal tool. Hold the 19mm wrench and spin the 10mm clockwise toward the driver side. A MUCH longer wrench would have been helpful, but it’s MIA. Ratchet and socket could work if you have one that is slimmer than average.

It’s pretty much impossible to see what I’m doing here, but I used a pry bar to release tension on the belt to facilitate spinning the pulley off of the alternator shaft. This is the point that I decided I’m not saving significant time by “cheating”, and pulled the alternator to reinstall the OAD pulley.

Degreased OEM pulley. Posting in the event someone wants to attempt to purchase OEM parts at some point.

Replacement OAD Pulley.
Litens P/N 920080A. Don’t know why the “A” isn’t stamped on the part, but it’s the part number that I purchased.

Reassembly is obviously the same as disassembly, only in reverse. I would suggest belt replacement at the same time as you’re already knee deep into the stuff you need to remove anyway, but my local parts house was out of stock and my belt has plenty of life in it.

I’m into the job about an hour in time, and about $100 for the pulley and the tool. All in all not as much as a PITA as I was expecting.

Hi Jamz,

Is there a torque for the pulley? And do you happen to know the alternator torques? I've had the part for a while and I'm hoping to get it installed this weekend. Just want to make sure I have everything I need to avoid multiple trips to autozone.

Thanks!@

 

[jaymz]

I do not. I just put an impact wrench on it until it was tight. I really don’t think you can overdo it. I’ve been an auto tech for nearly 4 decades and have kinda developed a “feel” for sufficient torque.

 

[Hokti]

I do not. I just put an impact wrench on it until it was tight. I really don’t think you can overdo it. I’ve been an auto tech for nearly 4 decades and have kinda developed a “feel” for sufficient torque.

Thank you! I'll try and feel it out.

 

[Trav73]

Hi thanks for the information, I was not sure what this was coming from until I read your posted. In your option does this look like it's time for immediate replacement or can I run as is for now? TIA

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