Can't torque down my alternator nut
 

Im in the process of changing out an alternator ground wire. Currently I'm putting the fan/pulley system back on.

The alternator and fan shroud is in. I'm Sliding the fan back on, then putting the belt on place, then putting 2 shims (like it was when I took it off), sliding on the pully halve, putting on the other 4 shims with the cup washer. Then I start tightening the nut onto the alternator screw. It tightens to a point, then I just start turning the alternator.

I feel like my fan needs to be seated on the alternator bolt somehow so I'll have the resistance needed to tighten the bolt when I'm using my pulley wrench (which is mated/seated to the fan) and my 24mm socket.

What the heck am I missing? I feel like its something so obvious...

Do you have the original tool kit? There should be a spanner wrench that allows you to hold the pulley while you tighten the nut. And the pulley is on a woodruff key way on the alternator, so it shouldn't move with the tool kit wrench.

The woodruff key you speak of. This is what I'm missing. It's not on the alternator shaft anywhere. There's a place for it in the fan though, like a nook cut out to mate with something on the shaft (wow this sounds like it should go on some other type of forum...if you know what I mean). But it's not there.

There is a place where the fan will mate to the pulley halve, but this unit isn't connected to the alternator shaft in any way so it just spins freely.

the key is the key to keeping it all together.

I had my pulley off to change the fan belt and the woodruff key dropped into the engine tray abyss where it would require a drop to recover it. I went to Napa, bought a bunch that looked like they may fit and after finding the right one, returned the rest. I put a bunch of rags under the pulley while re-installing the new key so it wouldn't drop down there again....

Can you fish around down in the crankshaft pulley area with a flexible magnet , and see if you can fish it out? You will be sure to bring up at least a few washers, a nut or two, and who knows what else .

did u put that thick cone shaped washer under the fan? if u didnt the bolt would bottom out like u described

I dropped my key down the "pulley trap" as well, fished it out with a flexible magnet like fastfred mentioned.
The other thing that really helps is putting a little grease in the slot on the alternator shaft to hold the key in place while you slide the fan back on. Otherwise, the key will just ride up out of the slot. Another one to watch out for is that none of the shims slide down over the end of the shaft when you are tightening the nut, or you can bend them.

If possible can someone post a picture of this key so I know what to look for. You all have been a great help.

I thought I was going crazy.

The cup washer outer diameter faces the fan.

This is NOT a Porsche alt. but the key looks like this
http://forums.pelicanparts.com/uploa...1341155499.jpg

Ok, I understand how the woodruff key works, but my alternator shaft has no saddle to sit in. Is there any other way to mate the fan with the alternator shaft?

is there a allen socket in the end of the alt. shaft?

There is! What does that mean?

you might have a newer alternator.

James Brown, Yeah. It is newer. I believe it's a Bosch and the previous owner put it in in 2005.

So how do I do it? If I've got my socket wrench on I can't access the Allen bolt.

Box wrench, allen key inside....

you just hold it and use the spanner to tighten the nut. yeah if it is a 5mm allen, use a 5mm box wrench on the allen to hold it.

So then, will my fan still turn properly to cool? It seems like it would have the tendency to slip on the shaft.

And I won't even need to use the pulley wrench...