Alternator Woodrfuff key placement
 

Thanks to everyone who commented on my post regarding separating the fan from the housing. Just took a little heat at the post and a little tapping. Alternator now has a new VR and is ready to go back in. Reattaching those little 10mm nuts to the air direction foil is not a fun job!
My current issue is the Woodruff Key. I am not certain if the key should protrude from it's slot at all or be completely flush. It's super tight and doesn't seem to want to go any deeper and I'm nervous about applying to much pressure. The fan turns freely without any scraping but not with the woodruff key in place so I'm inclined to think I've got this wrong. If anyone has a photo of the fan off and the key in place I would love to see it. Also, bonus points if anyone can confirm that I have the orientation of the spacer correct. It popped out when I separated the fan and I did not capture it with a photo to check. Many thanks all, I would not be able to tackle these things as a novice wrencher without the patient help from you experts!

http://forums.pelicanparts.com/uploa...1720219230.jpg

It has to protrude because that's what a woodruff key is for.
On your picture it appears to be slightly tilted towards front of axle, so you may want to pop it out and put it back making sure it is at even depth. No need to press it in too hard, so long as it fits into the notch on the fan hub.

If the woodruff key does not fit snug, if can slip out when you insert the fan. To remedy this, take a sharp metal punch and place a few divots in the key to make it snug when you tap it in. John Walker saved me on my new alternator with a new loose key!

Your sub washer is incorrect. Turn it over.
You want the key to be tilted to be sure you can get fan started, installed, the fan will balance the key.
Bruce

Use a little anti sieze on it also.

Thanks Bruce, That was close! I almost left it that way. Alternator went in fine but I had to go with 1 shim on the inside and 5 on the outside to get the belt tight. I may have to play with that some more, not sure if that's bad. Voltage meter reads 14+V for my whole drive but now the engine is running hotter than it normally does and I don't know if its related. Any thoughts?

That’s a good voltage reading.For running hotter, Is your air deflector on correctly? I think it only goes on one way though. It’s been hot here in the southwest.