Are there varoius sizes of pulleys for the different options on an s60? I just changed the alternator on our s60 and the pulley on the new one had a slightly smaller OD than the one I took off the car. I tried to get them to change the pulley at the store but the new one has a not centered nut and wouldnt break free. Now at idle the car doesnt put out the required voltage (11.75v at idle) unless I rev it up above 1k rmps. A smaller pulley would make the shaft turn less and could be the problem however the auto parts store has shipped back the alternator already. Is it possiable to change just the pulley without removing the whole alternator again?

 

A smaller pulley would turn faster, but you've lost the tension necessary to turn it.
Yes, you can and should change the pulley. Try to find one at the junk/salvage yard. Your local starter/alternator shop could also help. They've got spare parts and are often quite reasonable and accommodating.
Ed

 

I do have the same question,are there different pulley sizes for s60? A friend of mine told me that pulleys can be manufactured as per their specific requirements..

 

There are two pulleys, one is clutched and the other is the plain, solid variety. They are both the same diameter. Pulleys are made to order every day- by the manufacturers. The primary limiting factor is the length of the belt. The double sided serpentine belt can't be had in 1/2" increments like the typical V belt.
Ed

 

Can the solid pulley alternator be used in place of the clutched version?
The alt. went out on my daughters '01 S60 T5 today and the only one we could find was one with a solid pulley. I'd swap the pulleys but can't find the correct tool to remove the clutch pulley.

 

Don't replace a clutched pulley with a solid pulley. The clutched pulley allows the alternator rotor to overrun and reduces the stress on everything in the serpentine belt path. If you install a solid pulley you'll see your serpentine belt tensioner jumping around and may wind up breaking the alternator shaft or worse.

The Volvo tools are difficult to find - 9995760 and 9995761 - counterhold and socket, but you can also buy the tools - and the clutch pulley - from Vensel Enterprises 1-800-662-6099.

Update: here's the cheapest way I've found to buy the 33 spline tool that you need to hold the alternator pulley. The T50 Torx bit that comes with it is only for Bosch alternators so you can't use that.

 

The cars were produced with both versions. There should be no problem as long as the pulley diameters are the same, which they are.
The clutched pulley is pricey and is probably harder to get, and then there's the matter of a tool that is days away.
Hit the salvage yard for another, then you can deal with the first at your leisure.
I often recommend checking out your local starter/alternator shop for help, they're eager to help at a reasonable cost.

As far as the tool: http://www.amazon.com/gp/product/B00...=5336118877-20, It looks correct and not too bad for a tool you'll use only once.
The torx holds the shaft and the splines catch the pulley. The pulleys below the tool ad are also an option.
Ed

 

The clutched pulley is a stock item at your Volvo dealer. I guess I have a different perspective as my philosophy is to assemble all the correct tools and parts before I start a job. I prefer to pay overnight shipping if necessary rather than go driving around trying to find a junkyard part. Overnight shipping on the Amazon tool (for me) is $17.49. Cheap.

As I said in the comment above yours, the T-50 Torx bit is only for Bosch alternators. The Denso alternator on my car (2000 V40) requires a 10mm thin wall socket or nut driver to hold the alternator shaft. The 33 spline tool is good though.

I won't install a solid pulley on an alternator where a clutched pulley is original equipment. Reason? Worst case you can wind up with a derailed timing belt after the solid pulley comes off the alternator shaft.

 

I just checked. The old alternator is a Bosch and it appears to be original, as it has Volvo on it in a couple of places. Both the old and new alternator have a Torx in the alternator shaft. I ordered the tool from Amazon, it should be here Tuesday. I'll get a few uses out of it, we have 2 S60's and I'll be able to swap the old pulleys for new ones at a more convenient time. I think I read somewhere that the torque spec on the pulley is 65 ft lbs.

Thanks for all the help guys.

 

That's cool. 65 ft.lbs. it is. You should check the clutch pulley on the old alternator right now. They tend to last no more than 100,000 miles and you wouldn't want to swap a bad pulley onto the new alternator. Lock the alternator rotor with a screwdriver inserted into the alternator fan through the slots in the case on the pulley side and try and turn the pulley. The pulley should turn one way but not the other while the alternator rotor is stationary. It may be fairly hard to turn.

On your two S60s you may be able to swap the pulleys without removing the alternator from the car. I've done that before on a Volkswagen and I'm about to attempt that on my 2000 V40. (My V40 has a Denso alternator with a 10mm hex on the shaft.) I would have brought this up before if I'd known you have Bosch alternators on your Volvos, but there's a kit available for VWs that's designed specifically to allow you to replace the pulley with the alternator still in the car. It has a short T-50 Torx bit that requires very little clearance. Metalnerd Part MN3400 - Serrated Alternator Pulley Bit SET - you'll have to scroll down to find it.

Also, my trick for removing alternator pulleys on the vehicle is to soak a cotton ball in Kroil and stuff it into the recess in the center of the alternator pulley and leave it for a couple of hours. The cotton ball holds the Kroil against the alternator shaft threads so it can wick in. Without this, it's a bear to get the pulley off without removing the alternator from the car.