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Old 07-06-2013, 10:52 PM
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OilHammer OilHammer is offline
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Join Date: Apr 2009
Location: Denver
Posts: 1,479
Default Alternator pulley problem

My alternator on my 40 died and the replacements are all disco'd. I could have mine rebuilt to the tune of $500-600 or I could adapt the truck to take a "modern" alternator. I decided to try the later path first, but I've run into a snag. I'm okay with fabricating a bracket, and I'm okay with making an adapter harness to wire it up. My current issue is the pulley. I didn't notice in the pictures of the new alt that the v belts were TINY compared to the Toyota stuff. So I need to figure out how to get a proper pulley on there.

Option A: Make of find a sleeve that will adapt my Toyota pulley to the smaller and longer shaft of the Isuzu alternator. Sleeve would need to be somewhere close to 16.8mm ID to 19.8 mm OD. I found a 17x20mm bushing on McMaster, but it would likely need to be machined a bit and will have a tiny bit of play.

Option B: Find a different pulley that fits the Isuzu shaft, uses the appropriate sized v belt, and aligns fairly well. Since I haven't finished the adapter, I can adjust the alignment if I need to.

Option C: Make a custom pulley. I really don't want to go this route, however, I could make a dual V belt and be able to adapt a York on there later if I really wanted to.

Anybody have advice and/or resources to do this? I need to get this back on the road and have yet to find a quick & perfect fix for this.
1978 13BT-40, 70 series mechanicals
1966 FJ45 lwb stock
2003 100 OME lift
1974V8J40, 1992FJ80, 1985FJ60, 1971FJ55, 1978FJ40, 1974FJ40, 1997 LX450 all long gone.
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