Can not seperate Alternator fan from Housing
 

I followed the tutorial and it says to just tap the bolts lightly to get the housing to separate from the alternator. I am afraid if I tap the bolts any harder I will flatten the threads. I did remove the nuts from the bolts. I can not find any additional documentation. Does anyone have any tricks or tips on how to get these two separated?

I have tried the Technical article below

http://www.pelican parts.com/tech articles/911_alt_replace/911_alt_replace.htm

I have also tried the suggestion in, "101 things to do with your 911"

I need a way to get the two apart without breaking anything :)


:confused:
http://forums.pelicanparts.com/uploa...1233515737.jpg

any tutorial that says to beat on the bolts is to be ignored. fold several rags to use as a cushion and lay them on the floor, or get a chunk of wood and do the same. hold the unit in both hands, fan facing down, and knock the edge of the housing firmly on the rags/wood. turn 180° and repeat until it falls out.

FWIW, I dropped mine onto a couple of 2x4's setting on a towel and it came right out. Also, welcome to the forum- please add your location to your profile so we can better help you.

+1 What John said. It seems so simple to get it out once it is "knocked loose."

Of course 98% of the time, John's advice should be followed. The other 2% is for the process that have two perfectly good way to do the same thing.

Put a couple of nuts on the bolts before you beat on them to protect the treads.

John

Just did this yesterday with JWW method. worked perfectly.

You see? The workshop manual is right here!

I'm trying to break my fan assembly down and having very poor luck. As far as the upside down tapping method I think I could throw mine off a cliff and it'd stay together. I left the housing on the wood blocks after some spirited dropping and took a drift around the alternator as close to the edge as the housing will allow but it still hasn't budged.

Just to be sure - all that is required to remove the alternator from the housing is to remove the 6 nuts from the studs that protrude through the Fan housing, correct? I suppose I should just hit it harder but I think I'm on the verge of hitting it hard enough to cause damage as it is.

Of all the ways, I prefer the 2, 2x4s and drop the housing on them..But you should pull the fan first.
Bruce

I've had the same frustrating experience… Was also at the point of worrying about damaging something so I decided to end the effort and consult an expert. I put the unit in the back of my SUV and took it by a friends shop at lunch the next day. I went in the shop and explained my dilemma… got the unit and my 2x4's out of the car, (it was very hot late July - Aug in NC) and the 1st bump the thing fell apart... so this type of heating works well!

Twice I have failed to follow John Walker's advice and it was a mistake each time.

+1 for the John Walker method (thank you JW).

I used some PB Blaster on it before I came in and wrote the reply. I went out and got creative with a 2-Jaw puller and a pry bar to remove the fan and then got progress almost immediately when I started tapping the housing. Either removing the fan made a big difference or the penetraiting oil did; not sure which.

That's the way I did it and it worked great.

+1 on the JW method, I bent my bolts banging on them before I heard about it, didn't get it out that way, AND it cost me some money on the core charge for refurbishment. Regardless of what some people may tell you, as long as the housing and alt are original, it is NOT a press fit, it's just tight and sometimes gets stuck, but be patient and it'll come out.

PO of my alternator DID not follow the JW method, and one of the studs is gummed up and will not take a nut.

Assuming they are so bad you can't start chasing them typically you can take a file starting further back on the stud/bolt where you have good threads and work your way out. If it's bent, straighten it first. Most threads can be saved in just a minute or two. Theres so much extra stud on these you could just clip the damged end off, more than likely.

JW's method works like a charm!
But how do you separate the fan from the alternator's shaft, looks like a pretty difficult job and I just sprayed penetrating fluid and wait for miracle.

I threaded 2 holes on the fan, screwed in 2 long bolts, and used a puller. That worked.