Time to replace this pulley?
 

Beautiful day today in the Chicagoland area so hopped in the Targa and drove to work. I noticed an odd metallic rattling noise coming form the engine bay as I was driving. When I got to work I let the engine cool down and then started to poke around. I thought at first something on the exhaust might be loose but no dice. Then, as I was looking around I spotted this <photo attached>, two big metal shavings under the alternator pulley nut. There's a LOT of play in the pulley and when running the belt looks like a wet spaghetti noodle flopping around. <Hopefully the links to the videos work.>

Before I order up a new pulley, is there anything else should I replace while I'm in there? And are there any tricks, or things I should be aware of, before diving into this?

Thanks in advance, y'all have been super helpful as I navigate my way through air-cooled Porsche ownership.

https://photos.app.goo.gl/e5rmnZk9UWUrGkpb6

https://photos.app.goo.gl/2MvMcGi7FVEsq2u66

http://forums.pelicanparts.com/uploa...1660084200.jpg

May just be a couple of the 6 spacers that worked loose.

Looks like you may need to replace your shims as well

You're going to need all six shims since the ones between the pulley halves have been spinning as the outer half rotated independently from the inner; so presume those are worn.

I would also replace the outer pulley, as you noted, as well as a new nut (why did it loosen???) and the conical washer. I would just presume all those parts have been compromised by being loose and spinning around.

At least you can keep the belt.

Thanks so much for the input everyone. Loading up my cart right now with the following items:
Shim Washer for Alternator Belt Pulley (0.5 mm) x 6
Alternator Pulley Nut
Marchal Alternator Pulley Cover
Alternator Pulley (Single 82 mm)

Am I missing anything?

Silver lining. 🤣

Shims, pulley 1/2, and fan or fan hub. The holes don’t line up, so the flats on the pulley1/2 and probably the fan hub are damaged.

The outer pulley has some serious ganarfs on it, prolly from someone trying to grab it with large water pump pliers or pipe wrench. Recommend you add the proper nut removal tool to your part list if you don't have one already. If you have the factory tool kit you may find one there or I'm sure our host still carries them.

Grab a few extra shims. They’re cheap and I’ve destroyed one before.

It looks like your nut/shims and pulley ere not torqued down enough that the shims were spinning until they disintegrated. Also the outer shell is out of round and looks pretty beat up.

The below pic is what you need to replace. Just remember that there are two alternator shaft sizes depending on the model year. My 80SC had the smaller alternator shaft and when I replaced it with the CR 175 amp alternator I had to ream out the round domed washer to allow for the larger alternator shaft.

http://forums.pelicanparts.com/uploa...1660136284.jpg

Pulley setup with the CR 175 amp alternator.

http://forums.pelicanparts.com/uploa...1660136666.jpg

I have a 1980 Targa as well. Thanks for the photos, so far those are all the things I have in my cart. Plan is to take everything off and inspect everything before I place my order, just in case there's something hiding in there that also needs replaced.

Just to clarify parts on left are for the original alternator and the three parts on the right came with the larger shaft CR 175 amp alternator.

Quick update. Managed to get the pulley off, it actually took two of us using pry bars to get the nut loose. Someone used ALL the uggaduggas when they put that sucker on.

The pulley looks different than the ones I've been seeing though, it has two tabs on the inside that the others don't have.

There's also a tiny bit of front to back play in the fan with everything removed, is that normal? Best to just replace the fan too, just in case?

http://forums.pelicanparts.com/uploa...1660246890.jpg
http://forums.pelicanparts.com/uploa...1660246890.jpg

And yes, there were only one and a half shims all told.

That outer pulley is toast.

There should be a total of 6 shims, as you know.

The fan-side (hub) pulley boss (the squared off sides) has been mangled and at a minimum needs to be repaired - you can see where the formerly square sides of the outer pulley have worn into the center of the hub.

I recommend taking the fan off the shaft and make sure the woodruf key is still there. You may need a new one. When fitted there should be little movement, not necessarily none, but not much either. If there is a lot of movement you may need a new fan hub.

I'm not sure why someone attempted staking the rivets; maybe they thought the hub was loose, not noticing the machining going on at the pulley.

If you have to replace the fan hub, I suggest looking up some of the folks that restore these expensive fans. You could also send the fan shroud and get them nicely refreshed and preserved.

If you haven't already discovered, the fan is probably corroded onto the alt shaft. Instead of prying, pounding, hammering, jimmy-jacking, the wheel, try this:

Soak the wheel/shaft interface with any oil penetrant. Thread two of the 16 holes, 180 degrees from each other with whatever thread pitch/tap fits the hole. Then screw a bolt into each hole making sure the bolt goes thru the wheel and bottoms on the alt housing. Then alternate tightening each bolt 1/4 turn at a time until the wheel pops off the shaft.

Viola! No broken unobtanium fan blades or fan shroud.

Position of outer pulley to the shaft appears off-center. Looks shifted up towards 10 o'clock. Might want to compare this position to the position of the new outer pulley. Also, if fan is removed with difficulty, if you clean the alternator shaft and respective bore in the fan and then put a very light coating of antiseize on the shaft, the fan will always come off easily.
.

Slight thread hijack… my car came with a CR 175A alternator but only has the domed washer and the nut - no flat washer and no lock washer. Should I be worried?