Alternator Pulley / Clutch: Service and Repair

REMOVAL
The generator decoupler is used only with certain engines.

Generator Decoupler Pulley (INA):

Generator Decoupler Pulley (LITENS):

Two different type generator decoupler pulleys are used. One can be identified by the use of machined splines. The other can be identified by a hex opening and will not use splines.

Different special tools are required to service each different decoupler. Refer to following procedure.

INA Decoupler
1. Disconnect negative battery cable.
2. Remove generator and accessory drive belt. Refer to Generator Removal.

#8823 Tool And INA Decoupler:

3. Position Special Tool #8823 (VM.1048) into decoupler.

End Of Generator Shaft (HEX):

End Of Generator Shaft (SPLINED):

Decoupler Removal (INA-HEX):

Decoupler Removal (INA-SPLINED):

4. Determine if end of generator shaft is hex shaped or is splined. If hex is used, insert a 10 MM deep socket into tool #8823 (VM.1048). If splined, insert a 5/16" 6-point hex driver, or a 10 MM 12-point triple square driver into tool #8823 (VM.1048).
5. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise.
6. After breaking loose with tool, unthread decoupler by hand from generator.

Litens Decoupler
1. Disconnect negative battery cable.
2. Remove generator and accessory drive belt. Refer to Generator Removal.

# 8433 Tool And Litens Decoupler:

3. Position Special Tool #8433 into decoupler. Align to hex end of generator shaft.

Decoupler Removal (LITENS):

4. The generator shaft uses conventional right-hand threads to attach decoupler. To break decoupler loose from generator threads, rotate end of tool clockwise.
5. After breaking loose with tool, unthread decoupler by hand from generator.

INSTALLATION

INA Decoupler
1. Thread decoupler pulley onto generator shaft by hand (right-hand threads).
2. Position Special Tool #8823 (VM.1048) into decoupler.

Decoupler Installation (INA-HEX):

Decoupler Installation (INA SPLINED):

3. Determine if end of generator shaft is hex shaped or is splined. If hex is used, insert a 10MM deep socket into tool #8823 (VM.1048). If splined, insert a 5/16" 6-point hex driver, or a 10MM 12-point triple square driver into tool #8823 (VM.1048).
4. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counter-clockwise rotation. Refer to torque specifications.
5. Install accessory drive belt, and generator. Refer to Generator Installation.
6. Connect negative battery cable.

Litens Decoupler
1. Thread decoupler pulley onto generator shaft by hand (right-hand threads).
2. Position Special Tool 8433 into decoupler. Align tool to hex end of generator shaft.

Decoupler Installation (Litens):

3. Do not use an adjustable, ratcheting "click type" torque wrench. Most "click type" wrenches will only allow torque to be applied in a clockwise rotation. Use a dial-type or beam-type wrench. Tighten in counter-clockwise rotation. Refer to torque specifications.
4. Install accessory drive belt, and generator. Refer to Generator Installation.
5. Connect negative battery cable.