The 6-Series alternator?s pulley is held in place by a nut and lockwasher. A hexagonal indent is provided in the end of the pulley shaft, should it be necessary to remove the nut with hand tools. It is preferable to use an electrical or pneumatic impact wrench to remove the pulley nut from the pulley shaft. A 15/16? or 24mm impact wrench socket is required. To remove the pulley: 1. Loosen and remove pulley nut. 2. Remove lock washer. 3. Remove pulley. During disassembly, keep parts separated and in order to ensure they are properly replaced when the alternator is re-assembled.
Once the rear assemblies have been removed, the alternator case can be opened. To split the case: 1. Remove the stator wire isolating retainer from the wires and save. 2. Carefully pry the front and rear cases apart, using care to ensure the cases are spread evenly around their perimeters. The humps where the the four case bolt holes extend through the front and rear cases provide optimal pry points. Note: The stator and front bearing will typically remain in the faceplate when the case is opened. The rear bearing may remain on the rotor shaft or in the brushholder assembly. The following steps describe bearing removal.