Archived Kilby Generator Pulley Replacement

[drury]

OK. I set aside the weekend to put the Kilby air compressor kit on, and I got to this step:

7. Replace the generator pulley with the combo pulley supplied in the kit.

Does anybody know how to do this? I've got an '06, and the Bosch generator pully appears to be held on by some sort of weird spline nut. I took it to Pep Boys & Napa, and they were both clueless. The dealership is closed, but the service manual says that any problem whatsoever with the generator is to be resolved by R&R'ing the entire unit, so I don't think they are going to be helpful on this issue. (Actually, I don't think dealerships are set up to be helpful on any issue).



The truck is down until I can find a way to replace this pulley and put the generator back on the truck.

 

[drury]

Here's a couple of pictures of the pulley in question:

#ad


#ad

 

[rubberneck]

drury, just came across this thread. Hope you got it figured out, but in case you didn't i ran in to the same issue about 6 months ago. There is a special tool to back the nut off. The small spline is a long shank#10 spline drive and you hold that while backing the larger splined nut off. I do not remember the part number or manufacturer of the larger spline socket, but will get it from my dad. My snap on dealer got both tools for me. You then need to get a nut from an earlier truck to put the kilby pulley on. I emailed this info to Kilby when we ran into the problem so he could pass it along to other 2006 owners. Guess they aren't doing that.



BTW, the alternator is basically the same as all the others, the new pulley has an overrunning clutch built into it to stop the belt squeeling issue on shut down. Somebody got paid a lot of money to design a fix for an issue that wasn't really an issue in my book. LOL

 

[drury]

Fortunately, I live within an hour of Kilby Enterprises and Brad had the tool. He probably had it because of your email way back when. Anyway, Brad took care of it for me. He said it was his first chance to actually use the tool. He said the tool cost $50, which seems a little high for a glorified bolt.



I have noticed my belts squealing on shut down now. So you are saying that's because I replaced the generator pulley? I was thinking that maybe I had the V-belt tension too loose or too tight.

 

[MAshley]

Fortunately, I live within an hour of Kilby Enterprises and Brad had the tool. He probably had it because of your email way back when. Anyway, Brad took care of it for me. He said it was his first chance to actually use the tool. He said the tool cost $50, which seems a little high for a glorified bolt.



I have noticed my belts squealing on shut down now. So you are saying that's because I replaced the generator pulley? I was thinking that maybe I had the V-belt tension too loose or too tight.

..... Actually I told Brad about that stupid special bearing - nut on the alternator in December of 05 ... It took me 6 hrs of driving around to find a guy, who happend to be at his friends work for lunch who happend to have 3 years prior to have boughten the tool, who actuall happen to have it in his truck. And yes I do get some squele from time to time now.