Only 2 shims, here's my pulley: is it all over for my pulley?

[H.G.P.]

I got the nut off, here is what came off in order from left to right, and a close up of my pulley:


The order they came off was.....1. nut, 2. "washer", 3. shim, 4 wobbly pulley, 5. a broken shim:

........... for a grand total of ONLY 2 SHIMS.

I'm assuming the others must have broken off or disintegrated, as indicated from the second shim. Yet somehow, the alternator continued to operate.

Is my pulley normal? ...... it's round in the middle, however the alternator shaft has what looks like a rectangular pulley receptor.

[jmohn]

Yes, that pulley half is "toast". It should have a "rectangular" hole to fit on the "rectangular" portion of the alternator shaft. I advise to buy all new ... pulley, shims, washer and nut. BTW, how'd you finally get it off?

Jerry M
'78 SC

[H.G.P.]

... I bought a Stanley no. 7-85-710 long handle socket for more leverage, then used the pulley wrench on the top (I had been using it from below), and somehow would'nt you know it, the nut gave.

Now I've done a search and can't find a pulley for sale anywhere! (I'd like a new one) Neither do I see shims advertised. I wonder if there are other compatible pulleys or what not ??

[jmohn]

I see Pelican has them for the 912, but they don't show for the 911 of your vintage. This may be worth a phone call, the on-line catalogue doesn't show everthing they have. Otherwise you may have to "bite the bullet" and call a dealer.

Jerry M
'78

[dad911]

You may want to show us a pic of the fan. Usually the mating surface gets hammerred when the pulley is worn like that. If the 'flat' surfaces are worn, you will probably have problems.

Do an online catalog search above for 'pulley shim' and you will see that our host sells the shims and outer pulley halves:
http://www.pelicanparts.com/cgi-bin/autocat/load_page.cgi?page_number=3&bookmark=5&model=911M&currsection=enginD

[RoninLB]

is the fan hub worn at the foreward end of the curve/as it blends with the flat?

[H.G.P.]

Here's the fan pic:

[Jim Sims]

The following are listed here on-line at Pelican:

Outer pulley half: A-603-421-01 for $18.60;
alternator belt 10 x 710 K-192-176-50 for $4.95;
pulley shims A-105-561-00 $1.10 each;
an alternator nut for a Bosch Alternator is also listed.

The domed or cupped washer is not listed here at Pelican; yours appears deformed (becoming flattened) from overtightening without enough shims in the grip. I suggest you find someone with a shop press and a bit of tooling who can press it back into shape so you can reuse it. New domed washers (in my experience) are a bit hard to find.

How do the alternator shaft threads look? Both they and the threads in the nut can be chased with thread restoring dies and tap.s

Jim

[RoninLB]

Originally posted by H.G.P.

Here's the fan pic:
[

I'm not in focus

[H.G.P.]

Originally posted by Jim Sims
.How do the alternator shaft threads look? Both they and the threads in the nut can be chased with thread restoring dies and tap.s

Jim

The threads look to be in excellent shape! The domed washer, I believe is still domed. It's outer side is not flattened.

[H.G.P.]

Originally posted by RoninLB
I'm not in focus

I do not know if this one is much clearer, but the only one left in this shoot:

[RoninLB]

Originally posted by H.G.P.

I do not know if this one is much clearer, but the only one left in this shoot:

it somewhat looks like the steel outer pully half has worn the fan hub.. so is the outer pully half misaligned?

[H.G.P.]

Originally posted by RoninLB
it somewhat looks like the steel outer pully half has worn the fan hub.. so is the outer pully half misaligned?

I have the outer pulley half off, and the underside looks surprisingly quite symmetrical. The alternator, where the pulley would lie, also looks flush when I place the pulley against it, and aim a flashlight downward

Also, the center of the outer pulley half, I would describe as an "oval", becoming a circle. So very fortunate, I believe, in ceasing to drive and inspect the rattle noise.

(one other side note, the fan belt also looks to be in good condition, although I do have a new one from Pelican handy)

[Jim Sims]

The inside of your domed washer looks pushed in (sort of a reverse curve) by the nut. You do not want the domed washer to contact the flats on the alternator shaft/fan bushing. It should span or "dome" over them. Jim

[H.G.P.]

Originally posted by Jim Sims
The inside of your domed washer looks pushed in (sort of a reverse curve) by the nut. You do not want the domed washer to contact the flats on the alternator shaft/fan bushing. It should span or "dome" over them. Jim

OK, back inside after checking.....The washer goes over the shaft without contacting the shaft, but just barely. I'll try to find/see a new one for comparison (if possible). Thanks!

[Wil Ferch]

When you buy a new pulley half....double check the diametrer size....there were many variations and some are "very" close in size....like 80 vs 83 mm on the alternator.
---Wil Ferch

[McDaniel]

It looks on the photo like there is a groove worn on the fan hub.
There was on mine when I had the same problem. The groove
is usually a circular shape, like for a Woodruf key...

[RoninLB]

Originally posted by Wil Ferch
....double check the diametrer size....there were many variations and some are "very" close in size....like 80 vs 83 mm on the alternator.

yeah.. I kept the high speed 5 blade fan pully on the 11 blade because I do mostly mid range rpm..........Ron

[HarryD]

HGP,

Glad to see you are making progress.

[H.G.P.]

Originally posted by Wil Ferch
When you buy a new pulley half....double check the diametrer size....there were many variations and some are "very" close in size....like 80 vs 83 mm on the alternator.
---Wil Ferch

The ones offered I believe are all 3.75" in diameter. Mine measures this, so hopefully will work out. I'm more concerned with those wrench holes that they'll line up after installation.

Thanks for the help.