Have you figure out what you are going to do for a new pulley yet? I have always installed factory Volvo or Bosch rebuilt alternators and they do not come with a fan or pulley and you are expected to use your existing. If that bolt destroy all of the fan blades on the back side of that pulley you are going to need a new one for sure. Next time, use a Bosch alternator if it is possible.

Also, what was wrong with the original alternator. 90+% of the alternators that I see go bad really just need a brush holder/regulator assembly as the brushes are worn down. In fact I routinely recommend and sell brush holders to my customers when they get up into the 175-200k range. It is a good, comparatively inexpensive upsell/repair. Keeps repair costs down and prevents my customer from having a costly unexpected repair.

Mark

Had the EXACT thing happen with my last rebuilt alternator. Mind had an ULTRA FUN twist though. the screw came out, put stress on the pulley, and loosened the main nut on the alternator shaft. Somehow it wiggled around so much it LOCKED tight onto the shaft, and even a 700 ft lb impact and a oxy torch couldn't remove it. It basically mated permanently with my volvo pulley.