How do I get my 2g pully to fit on my new 3g alt. I want the smaller pully so it charges better at idle since I have underdrives but the 2g pully rugs against the alt. Its nose isnot as long as the 3g's. How do I fix this? Any ideas?
My 3g pully is about 3/16 of an inch larger than my stock one. So at idle(apx725-750 rpm) with a/c and lights on I only have 12 volts, but at 1000 rpm it is a nice solid 14.2 volts. So eaither I have to figure out how to put on the stock pully or I have to find a stock crank pully and take off the underdrive.
Some 3G's on certain applications have a pulley close to the same size as the 2G's, but pretty much all of the reman'ed parts store alt's have the larger pulley.
You could try finding a very thin washer to put behind there, but that reduces the amount of thread you'll have available with which to crank the retaining nut down, so I wouldn't recommend going that route. Your best bet is really to just hunt the boneyards for any and every mid-90's and above Ford and see if you can find a pulley of equal size on a 3G alternator.
I was working at Autozone at the time I did mine, so I was able to just dig through the core bin at my workplace until I found a suitable donor pulley, and just swapped that for the big honkin' pulley that came with my reman'ed 3G. (I seriously doubt the reman company would give a crap, they appear to put new pullies on all of their alt's.) If you've got a buddy working for a parts store, you could maybe have them keep an eye out for one for ya', but again, your best bet's going to be with hunting the 'yards.
...or you could just special-order the pulley from a place online that has a specific-sized pulley, but 1. it's more expensive, and 2. I don't remember the name of the place right off hand.
when i took the stock 2g fan pulley off, i found a small diameter and very thin "washer" behind the fan. i put this washer on the 3g shaft and installed the stock 2g pulley. No problems with the pulley hitting the case or with alignment with the crank/rest of pulleys. It's been on there 3 years now.
Thanx, found it right where you said and it fits perfect. Now I just have to get a new nut because the 3g one flanges out so it does not grab enough thread to be safe, but thats at any autoparts store.
The nuts on my 2 alternators were different.
The stock '95 Mustang GT 3g pulley was the same size as the fox underdrive pulley so I used the stock fox pulley.
How about using an underdrive pulley for a '87-'93 5.0 2G alternator on a 3G alt? I was going to install underdrives and a 3G alt at the same time on my '91 and I was assuming I'd still get a decent charge at idle since the 3G puts out so much more power than the 2G even at idle. Or am I better off putting the stock 2G pulley on the 3G alt?