328 Alternator Pulley Issue

Well, ever since I got the '86 328 two years ago, I've had an ongoing issue with the alternator belt breaking. I bought the correct belts, and they seemed to work okay at first, but would then get chewed up and ultimately break. Last winter, I pulled the alternator and had it rebuilt, and the rebuilder said that it was having problems with the bearings and that probably caused the problem.

Well, we reinstalled the alternator last spring, and the car seemed to run fine. Then I started getting the same squealing that I had previously, before the belt would break. I put the car away in late fall and finally got around to pulling the alternator out today.

Check the pictures below. A problem? I think so. It seems this is not the right pulley for the belt, or has worn down so badly that the belt no longer sits properly. Not to mention the uneven surface and the steps in the V. No wonder it was chewing up the belt. Plus, when I pulled the pulley off the shaft, I think I found the source of the squealing -- the Woodruff key was missing, so the pulley could turn on the shaft.

So, does anyone know of a source for a properly sized pulley? Or can someone measure their 328 pulley, or provide me with a Bosch part number so I can order an new one?

Many thanks.

p.s. I did a search here and came across an interesting bit of information. I seems the prior owner of the car was also having a problem with the alternator belt breaking. I guess he didn't solve the problem. Hopefully, replacing the pulley with a properly sized one in good condition will solve the issue.
Image Unavailable, Please Login
Image Unavailable, Please Login
Image Unavailable, Please Login

 

Not so far. But I checked on line and some of the "usual suspects" list the pulley alone at over $350!! No way! I got the alternator rebuilt for less than that. I think I'm going to go back to the guy who did it for me. He had piles of parts laying all over the place for Bosch alternators. Hopefully, he will have something that will work. But knowing the dimensions of the stock pulley would be very helpful.

 

Does anyone have a Bosch part number for the 328 alternator for a 1986 GTS?

 

Thanks Bill. Yes, that is the part number for the alternator. I'm looking for a part number for the pulley. My alternator is good, I had it rebuilt last spring and it works fine. It's the pulley that's the problem, chewing up the belt. I definitely have the wrong pulley and need to get the correct one.

 

Jerry,

I looked at that possibility, but the problem is the offset. The OEM pulley has a long shaft on the back and deep offset, to project the pulley itself out past the end of the alternator shaft. You can't shim a regular pulley to get the pulley out far enough to line up with the crank damper. So trying to rig something up to work like that is not possible. I may have sourced a replacement from a helpful F-Chatter, so we'll see what happens. But thanks for the suggestion.

Steve