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Fresh air blower repaired for archive



Got around to investigating why the fresh air blower never worked. Found that one of the carbon bushes on the electric motor was kaput. The carbon bush was intact, however the plastic casing holding it had melted.



This occured because the motor rotor (attached to fan)and outer casing (attached to body) were not freely moving, causing the motor, and bush, to eventually overheat from high current draw.

So faced with trying to find a replacement carbon bush I decided it was worth the effort to try and repair first. Nothing ventured and all that.



The outer black casing, shown, was removed through release of four spring clips. I removed the two carbon bushes by snipping wire at the spade connector (as they could be resoldered). And disconnected a little internal spring which pulls the carbon bushes to the rotor.



I cleaned up the plastic housing as best I could to get a proper seating for the carbon bush. Then I stripped down a data cable into its individual fine strands of wire. Wrapped a number of threads around the bush and housing and secured with a couple of solder joints. (I notched the carbon stick in a few places to allow the wire grip hold). Not pretty, but effective.



Spent a while trying to free up the rotation of the housing. Eventually succeeded with screwdriver leverage and drop of oil. Ensured rotation was completely free.



As Magnus had shown the fan and motor can be separated, this requires a bit of hammering out of axle from fan, and would need to be done carefully so as not to damage either. Otherwise the area between motor casing and the fan can be oiled through a small access hole, see image



Unit is now back on the car and fully operational, and I expect it will be a while before the carbon bushes wear down to the repair wire. (Before you ask, thats what fuses are for).

So here is another repair job for the archives.
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Porsche 911E

Last edited by POKDUB; 12-07-2005 at 03:42 AM..
Old 12-06-2005, 12:35 AM
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Post this in the Tech Articles Section....good job!

Wil
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Old 12-06-2005, 03:18 AM
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I had the exact same damage on my blower last year.
I decided to get a new motor with new brushes and bearings. It was about $100+ something (expensive little bastard!).

I got it from a Bosch dealer and tapped out the old from the fan and pressed on the old fan to the new motor.
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Old 12-06-2005, 07:35 AM
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Old motor:



Fan:


New motor:

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911 Silver Targa -77, 3.2 -84 with custom ITBs and EFI
911T Coupe -69, 3.6, G50, "RSR", track day.
Old 12-06-2005, 07:43 AM
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Magnus,

Nice pictures, especially with full motor removed. I tried to remove the motor casing, but I can now see why it would not come out on its own, its wrapped around the rotor.

You can also see the hole on the white fan casing I referred to for dropping oil through.

My carbon bush looked exactly the same as yours, initially I thought it had broken, on closer inspection I found it melted back into the plastic.

Not an item to do without in Sweden, I love Stockholm, been there a couple of times this year.

Rgds
Peter
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Last edited by POKDUB; 12-06-2005 at 09:54 AM..
Old 12-06-2005, 08:40 AM
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Yeah, I tugged on mine to before I got the fan of the axle

Frankly I mostly use the fan in the summer when sitting stationary.

Yes, Stockholm is a nice town.
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Old 12-06-2005, 10:07 AM
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Magnus,

Hope you dont mind me using your photos to fill in the story and complete the repair guideline.

Rgds
Peter
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Last edited by POKDUB; 12-07-2005 at 01:19 AM..
Old 12-07-2005, 01:11 AM
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Peter, go ahead feel free to use them.
Here is some more pictures from the trunc if they are any help.



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Old 12-07-2005, 03:06 AM
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Hi ,

i would like to add my experience on this fresh air blower motor

I own a 69 and my blower was out of order due to this small bosch motor.
therefore i replace the old one by a new bosch motor.
i add to cut off the small plastic cover on the new bosch motor to fit perfectly with the casing and to grind a bit the casing.







Last edited by thor; 06-16-2014 at 06:48 AM..
Old 06-14-2014, 10:21 AM
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just a question :

you know the water drain hose for the air box is not anymore available ,

what is other possibilities you have found to replace it ?

thanks
Old 06-15-2014, 03:59 AM
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Quote:
Originally Posted by thor View Post
just a question :

you know the water drain hose for the air box is not anymore available ,

what is other possibilities you have found to replace it ?

thanks
This washing machine drain hose is what I used. Trimmed the large (inlet) end down to fit the air box and cut to length.
Fit perfectly.
Outlet Drain Hose, 5' (PMB-449) at Aubuchon Hardware
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Old 06-15-2014, 05:46 AM
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thanks pete

excellent idee ))))
Old 06-15-2014, 06:00 AM
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Great writeup. Looks like I'm about to tackle this job myself.
Thanks!
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Old 06-16-2014, 06:39 AM
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Yes indeed the hose is the same that washing machine .
i ve done that and it fits perfectly
Old 06-23-2014, 02:08 AM
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