UPDATE: got it all apart, not easy! The outer half of the pulley was wobbly after I cut the belt. Figured no shims must be there. After some creative tries I got it apart. And NO shims present! The spindle on the alternator had some wear similar but not nearly a bad as TeeJayH shows in his thread. See pics below. I remembered there were a couple small parts that came with the car (I have had it about 6 weeks). Sure enough, zip tied together are six shims! Not new but in fine working shape. Somebody didn’t know what they were for when they put a belt on??
New shims, belt, outer pulley half, tension cap, nut and pulley wrench on their way to me from PP. But for now when I put 5 shims between pulley halves (per recommended place to start) the outer half seats properly (center is a bit worn out of shape but not bad) it snugs up well with the sixth shim on the outside u see the tension cap.
Will replace all when new pieces arrive with the new belt and see how it goes. Nothing to lose trying new parts.
Also, started the car with belt off, smooth and quiet. It had a top end rebuild 2500 miles ago and literally has no leaks. So relived to have isolated it to the alternator fan area. Even if it means a new alternator and fan, that’s less than an internal crankcase issue!
Will keep updating post new parts and time to get them in. Thanks again for the earlier input.
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