Hi All, hopefully someone can help me. I was having many electrical issues that I thought I solved by resoldering the instrument cluster. However, the car started really playing up with first the battery light and then loads of other warnings. I checked the output of the alternator and it was 10.5V so expected that the alternator was on its way out. I have now managed to take the old alternator out and now have 2 issues that I could really do with some advice. The over-run clutch on the alternator had no fixing attached to it and the recesses are now an odd shape. It also sits lower than the majority of the holes. I have ordered a second-hand replacement that looks like the cut-outs are still good. The question is what do the fixings look like as all 3 were missing?

Secondly, how do I get the pully off of the old alternator to put on the new alternator. Is there a special tool? Any help would be greatly appreciated.

Looks like you need a new clutch pulley assembly.

Not sure you have a 1.9 TDCi like you say in the heading, unless of course the cylinders are now very well worn 🤣

This is for the 1.8 TDCi EXAMPLE:   https://www.autodoc.co.uk/ridex/13636191#alternator-freewheel-clutch

 

Hub puller and pulley removal tool:

https://www.gsfcarparts.com/products/triple-leg-gear-reversible-puller-set-3pc-seavs77?gad_source=1&gclid=CjwKCAiAmfq6BhAsEiwAX1jsZ1y_LgrldhD2rKkjKub6-XMXoRKRVcH-NiEBnG5dgOLz1qH-J0B20RoCGjUQAvD_BwE

Hi unofix, thanks for the reply. The actual clutch part of the pulley seems fine as I can only rotate it in one direction. The problem is that it was not attached to the alternator with what I assume are 3 identical bolts as the are 3 threaded holes on the output pulley on the alternator. As for the hub puller, the issue is that I don't know the correct way to undo the nut that is holding the pulley on. It seems to be a 22mm nut but how do I undo it as the alternator is free to spin? If I do get it off how do I do it back up on the new alternator?

Here is a used unit on ebay showing the three fixing bolts. Yours appear to have worked loose and fallen out. This wore the slots larger as they were working loose.

Perhaps it was not charging properly as the outer part was only driving the pulley by friction. Possibly only the part with the worn holes needs to be replaced. The alternator itself may still be working.

https://www.ebay.co.uk/itm/156509106905

The new alternator will most likely be supplied with a pulley ready installed.

If not, the image appears to show a smaller hexagon formed into the end of the alternator shaft. That looks to be used to prevent the shaft from turning while a hollow wrench is used to undo the actual nut.

A 22mm Oxygen sensor socket such as this one and a suitably sized allen key or allen socket should work.

https://www.ebay.co.uk/itm/135308439794

I have managed to undo another type of alternator pulley nut in the past using an impact wrench. This will loosen the nut without turning the shaft. I refitted it by setting the impact wrench to turn in the opposite direction.

 

It may be worth finding a local alternator repair company. Some of these still exist.

They will be able to bench test the alternator. If it has failed, they may be able to replace the failed component.

Thanks for the reply AntonovAN12. I already have a new alternator and am waiting for a second hand over-run clutch assembly. I have 3 M6 short bolts to fit when I receive the assembly which I will thread lock in. The new alternator did not come with a pulley but I have managed to change it over at my place of work.

I would have been tempted to try marking and drilling three new holes. The slots could be cut with a hacksaw or carefully with an angle grinder and 1mm slitting disk.

Don't throw the old alternator away without having it tested. If the bearings turn smoothly it could be an easily replaceable regulator failure.

Not a comment on the mechanical issue, but I know the early Mk2 focuses had a problem with poor diodes in the alternators, mine blew on a 2006 1.8 TDCi I used to have, I got diodes replaced (by electrical specialist, didn't do job myself). Don't know if same alternator as 1.6 petrol though. 

Thanks for all the advice. I changed the alternator and used the old clutch due to the good old Royal Mail who appear to have lost my replacement. The car no longer makes a strange noise so that is fixed. I now have an issue of a P1204 error and a U2023 fault causing limp home mode. If it is an injector that is likely to be quite expensive unless anyone knows where there is an injector that is reasonably priced. I don't know if it is worth chasing another issue on an 09 car but will have a think about it over Xmas!