I've had a very slightly squeaky aux belt for a couple of weeks and had seen a couple of flickers of the charge light on the dash, so had planned to change the belt and tensioner this weekend. (we'll ignore the part about a colleague borrowing the car Friday/Saturday...) but I now have whats pictured below.

The shaft on the alternator which is badly scored, is that part of the alternator or does that come with a new pulley?

The way I believe the 2 piece removal tool works is that the outer splined part holds the alterator stator (my knackered shaft) whilst a bolt holds the clutched pulley assembly on, but I'm hoping that the central bolt actually holds that part of the stator on too, like an extension to the main shaft inside the alternator.

Should that, what is now a plain shaft, have some splines on it to drive the inside clutch on the pulley, or if its reasonably OK when cleaned up could it still be used as its just there to hold the pulley on?

Any pictures of a non-knackered setup, or the parts which come with a new pulley kit would be appreciated.

Thanks

Chris.

ps. if anybody wonders in the future, it managed 25+ miles with no alternator, just running the car on the battery, which was lucky! Another bonus for diesels

After taking the alternator off, it appears the damaged shaft is just a "bolt on" as part of the clutched pulley assy.

But, there is a slight noise from the alternator when its spun, so given the cost is only £50 extra for a whole new alt with pulley, which saves buying the tool as well, may as well fit a new alternator.

I'm also pretty sure its impossible to fit a new tensioner, which is locked in the tension position, when its pulley is attached. I had to remove the pulley to get enough space between the inner arch at alternator bracket, in order to fit. If the pulley isn't "wound up", then you can fit it, madness.

After taking the alternator off, it appears the damaged shaft is just a "bolt on" as part of the clutched pulley assy.

But, there is a slight noise from the alternator when its spun, so given the cost is only £50 extra for a whole new alt with pulley, which saves buying the tool as well, may as well fit a new alternator.

I'm also pretty sure its impossible to fit a new tensioner, which is locked in the tension position, when its pulley is attached. I had to remove the pulley to get enough space between the inner arch at alternator bracket, in order to fit. If the pulley isn't "wound up", then you can fit it, madness.

the "splines you can see are actualy the remains of ther needle bearings which used to grip or ride over the splines that used to be on the shaft having dismantles a noisy one it seems the greas "burns " then clogs the needles which then skid and slip it must have been noisy for some time, will try to find one for a pic

I have a couple of pulleys knocking around, I'll try and take a pic of one tomorrow. By the looks of it the centre of the pulley will still be attached to the alternator.

You will need the correct tool to remove the remains and attach the new pulley.

I'm not sure exactly what the layout of the engine is but if it's the same as the 130bhp PD engine a galaxy then the tensioner is quite easy to change, just three bolts and no need to remove the alternator.