Alternator repair, a little show and tell.

Hey Mattax! I myself am getting ready to remove an "ugly" just like yours. I however found another 2 belt pulley with more diameter. Like 1 or 2" more. Can you elaborate about pulley not fitting puller tool? I probably will run in with same issue!:(

I'll try to take some more photos today. Item 1 in the puller set illustration is supposed to slip onto the nose of the pulley.
upload_2019-3-20_8-28-55.png

On this pulley, the neck wasn't turned small enough.
upload_2019-3-20_8-33-43.png

My solution was to use a grinder and files. I put the alternator in a vise and coveredthe front with cardboard so the grindings and filings wouldn't get in it.
upload_2019-3-20_8-42-0.png

There's another type of puller shown in the service manuals. I actually had access to a partial puller set with that type of puller but couldn't find the right pieces to properly grab the nose.
upload_2019-3-20_8-48-9.png