Alternator Fan reinstall is stuck - any ideas?
 

Anybody have any quick tips for getting a fan to cooperate back onto the alternator shaft? I did search - I am resisting banging for fear of shifting the rotor/shaft/bearing.

I get the fan started onto the woodruff key, but I don't have any exposed threads so I can't start the nut.

I tried dressing the key a little with a small file. Fan was electroless nickel plated, I can't believe it would have made that much of a difference, but I took some emery paper to the inside of the fan.

Can I get away with using a soft mallet, or should I continue to use the emery?

Thanks

If it is that tight and you use the mallet it might be a one way deal.
Not Cool.

I tap mine one with a mallet, BUT I mean TAP. (Softly)

EMERY! Again.

Emery it is then, thanks.

I spent a good 30 minutes trying to get my fan back on. The problem was lining it up with the key. I would try and remove the plating as you've been doing. Bad things can happen with a hammer. Good luck.

it definitely lines up/sits on the key, but I'm thinking I used up any slop I had on the slot/keyway when it was plated. Thanks John

Maybe....But make sure your key is not moving around on you...
 

I have had a problem in the past when the key would slide upwards when reinstalling the fan over the alternator shaft and caused too tight of a fit and therefore not fully seat (stop). Just a thought, but make sure the key is not sliding too far back keeping the fan keyway from fitting over the key...f.y.i.

emory
 

use the emory on the inside of the fan and on the shaft to make it smooth and also try some PET or vasaline to help it along. You dont want to force it to much because you need to get a straight seat. I usually have trouble getting them off not on...

I recently had this problem. I could have sworn that fan or shroud was bent in some subtle way. The ultimate solution was to set alternator into fan that was then placed on top of a wooden box/holder I made for the purpose. I then placed deep socket and over alternator bolts and tapped VERY gently in a star pattern. Hope this helps.