Only time I removed one I used a press.

 

The old pulley comes out just with the puller tool.  If it doesn't come out, you could try WD40 or some other rust pentrator.  I've pulled a few and some are harder than others.  I would not apply heat at all.  Worst case take it to someone with experience.

For pressing on the new one, you need to remove the rear half of the case (unbolt/screw the 2 brushes first) so as not to damage the rear shaft bushing/bearing

 

Are you using a tool like this?: http://www.overstock.com/Home-Garden/Pulley-Puller-and-Installer-Set/3499191/product.html?cid=123620&fp=F&ci_src=14110944&ci_sku=11568313

 

Sorry it took me soo long to reply. I haven't had time to get to a computer and my phone would not open that link. You can see the puller im using here. I thinks its the same one the FSM refers to but dern if I can get it to move.

 

you got a zip gun [ air hammer ] with a center punch chisel

 

Have an air hammer but don't know about the center punch chisel

 

Once you do get the old pulley off, be careful with the March pulley.  All the ones I had were very soft aluminum and it was very easy to gouge and dent the alternator pulley while pressing it on.  They usually have a cover that screws on to dress it up that covers any marks you might make but you definitely want to apply the press force in close to the hub of the pulley.  Out to far on the diameter of the pulley and you could probably easily crush the belt groove.

 

Once you do get the old pulley off, be careful with the March pulley. All the ones I had were very soft aluminum and it was very easy to gouge and dent the alternator pulley while pressing it on. They usually have a cover that screws on to dress it up that covers any marks you might make but you definitely want to apply the press force in close to the hub of the pulley. Out to far on the diameter of the pulley and you could probably easily crush the belt groove.

x2. It's very delicate.

 

Once you do get the old pulley off, be careful with the March pulley. All the ones I had were very soft aluminum and it was very easy to gouge and dent the alternator pulley while pressing it on. They usually have a cover that screws on to dress it up that covers any marks you might make but you definitely want to apply the press force in close to the hub of the pulley. Out to far on the diameter of the pulley and you could probably easily crush the belt groove.

Ok, point taken. I still have to get the old one off though. Go figure, I get the worst one known to man. If I didnt have bad luck I'd have no luck at all. The terrible thing is, this alternator has 225 miles on it, just put it on my new motor.

 

Thanks for the help fellas. I got one of those pullers like mike suggested and the pulley came right off. Lesson learned: The FSM doesn't ALWAYS know best, there is a better tool for this than they suggest. I heated up the new pulley and it dropped right on, didnt have to apply any force at all.

 

Wish I had thought of that, lol. 

 

Thanks for the help fellas. I got one of those pullers like mike suggested and the pulley came right off. Lesson learned: The FSM doesn't ALWAYS know best, there is a better tool for this than they suggest. I heated up the new pulley and it dropped right on, didnt have to apply any force at all.

That's the tool set I have - works great.