I think I found the culprit!!

[Norm Faustino]

I was having trouble with my fan belt due to the shaft not being far enough out, so I took the fan off and I remember thinking this washer was a little thick when I assembled the motor. This sucker looks like it could be machined down some. Anyway, does anyone ahve a diagram of the shaft and it's related washers etc...?

[Norm Faustino]

Bump? Does anyone have the diagram for behind the fan?

[john walker's workshop]

looks normal.

[Norm Faustino]

John, I measured the thickness of the washer stacked on the fan shaft hub and it seems to be too thick, it doesn't seem to be allowing the fan to seat far enough to allow me to get the pulley nut started (see pics a couple of threads before this one). It seems in the pictures of everyone else's motor, that the pulley nut still has a few threads showing after final tightening, where mine has no thread protrusion above the nut at all.

[Jim Sims]

From an old thread:

Here's the order starting from the alternator face: (1) steel washer (may look yellow or gold from plating - magnet will show it is steel); if this washer is stepped (has two different diameters) the smaller diameter usually goes towards the alternator face. Line up the notch with the keyway in the alternator shaft, (2) Woodruff key (half moon-shaped piece) with curved edge down into keyway, (3) fan, (4) some of the shims, I suggest starting with three for first try, (5) outer pulley half, (6) balance (three but sometimes two depending on what came with the car originally) of shims, (7) cupped or domed washer (may look yellow or gold from plating - magnet will show that it is steel), concave or hollow side goes towards outer pulley half (towards alternator), and (8) alternator shaft nut. If one fails to install the washer behind the fan there is usually an obvious lack of alignment of the crank and fan pulley belt grooves.

I assume you know that all six shims should either be between the fan and outer pulley half or under the domed washer. On some of the later outer pulley halves which contain additional belt grooves (for air pumps) one must take care that the outer shim washers do not slip down and become offset and then become distorted when the alternator nut is tightened. It is important to ensure that the domed washer is not contacting the end features on the alternator shaft but insteads spans over them and contacts the stack of shims outside the outer pulley half. If contact with the end of the alternator shaft is occuring something is not right: pulley is lopsided, shims have slipped or you're missing a shim or shims.

[Jim Sims]

Are the fan shroud and alternator original or have they been replaced?

[Jim Sims]

Mystery Washer

[Norm Faustino]

Jim, the fan and housing are not my original parts but are original from another 78SC but I will check the standoff distance from the alternator support cage to the face of the housing, just to make sure. Good point! btw, and thank you for the help, you guys, I'm trying to get the motor ready to install inthe car once it comes back from paint and get it installed before I leave for Seattle, so I am very frustrated because I only want to hang this motor ONCE! But as the man says " whatchu want and whatchu get, are two different things son"