Help needed removing alternator from fan housing

[ned903]

i've managed to remove the alternator and housing from the car, but try as much as I can, I am unable to remove the alternator from the fan housing. I've tried tapping on the bolts and heating the housing, but nothing seems to work. Am I missing something? Any help is appreciated.

[James Brown]

one of the best ways is to drop the housing rear edge on a piece of wood like a 6x6 while holding the front edge and allow the inertia to drop the alt. out, be ready to catch the alt. rotate the housing between "drops" on the wood. Don't tap on the alt nose or housing, just gentle drops should do it.

[Flat6pac]

+1 dropping it on the wood blocks

[steely]

+1 this is the best method.

[yelcab1]

I just did this. Drop it on two 2x4. It slips out.

[Trakrat]

Sorry to bring up an old thread.... can someone post some pics or draw a diagram to tell me how this works?

I CAN...NOT.... get my alternator out of the fan housing.

[john walker's workshop]

Hold the housing with both hands, fan side down and knock the edge of the housing on a block of wood a couple of times, rotate 180 and do it again, repeat. Don't go animal and break the edge.

[Jack Stands]

And don’t hammer on the alternator bolts as they’ll mushroom out at the ends. Perhaps a small drop of oil along the studs to lubricate the dissimilar metals where they may have corroded from the dissimilar metals?

[Trakrat]

Originally Posted by john walker's workshop

Hold the housing with both hands, fan side down and knock the edge of the housing on a block of wood a couple of times, rotate 180 and do it again, repeat. Don't go animal and break the edge.

so the idea is to bang the fan housing on both sides of some wood until the alternator slips out and fall off of it?

And this won't crack or break the fan housing??

[Nux]

Put the whole thing in the oven for 10 min - it will slide right off.

[old man neri]

Essentially. As oppose to try to bang the alternator out of the housing you are banging the housing off the alternator using it's own momentum. Get the alternator and housing moving at a speed and the suddenly stop the housing.....the alternator should keep going.

[proporsche]

i do it as John W.said...on wood ,drop the edge of the housing ,with hand holding it and rotate. Use the weight and gravity....

Ivan

[al lkosmal]

Step 1. Listen to John
Step 2. Get two 4 X 4'S (official Porsche tool # P-4x4 )
Step 3. Position the fan housing so the outside rim of the housing rests on the edge of the 4x4's (as shown)
Step 4. Hold the housing, by the sides, with both hands.
Step 5. Raise the housing off of the 4 x 4's
Step 6. Quickly lower the housing to the 4 x 4's, allowing the rim of the housing to strike the 4x4's (not too hard...let the weight of the housing/alternator do most of the work)
Step 7. If the alternator did not drop out, rotate the housing a 1/4 turn and repeat steps 5 & 6...

Note: Prior to attempting this procedure, verify that you have removed all of the associated fasteners.

[mepstein]

we just use a press.

[Trackrash]

I have to chime in here. Last year I had to remove two alternators. At any rate, I dropped and banged down both of my housings repeatedly on 4 x 6s. To the point I thought the housing would shatter. Neither budged.

The problem is corrosion around where the housing meets the lip on the alternator. I soaked that area for days then used a mallet on a block of wood covering the studs. Working carefully back and forth till the corrosive glue gave way.

I think the oven idea is worth trying, I should have though about that. Press?

[john walker's workshop]

Can't say this method ever failed me. Some are more stuck than other of course and require more effort/time.

[KNS]

I assume the removal process is the same for the 964/993 alternator and fan..?

[Trakrat]

Originally Posted by al lkosmal

Step 1. Listen to John
Step 2. Get two 4 X 4'S (official Porsche tool # P-4x4 )
Step 3. Position the fan housing so the outside rim of the housing rests on the edge of the 4x4's (as shown)
Step 4. Hold the housing, by the sides, with both hands.
Step 5. Raise the housing off of the 4 x 4's
Step 6. Quickly lower the housing to the 4 x 4's, allowing the rim of the housing to strike the 4x4's (not too hard...let the weight of the housing/alternator do most of the work)
Step 7. If the alternator did not drop out, rotate the housing a 1/4 turn and repeat steps 5 & 6...

Note: Prior to attempting this procedure, verify that you have removed all of the associated fasteners.

perfect... thank you... I did this and after dropping it about 20 times from about a foot above the wood, it finally fell out.

[Trakrat]

Originally Posted by Jack Stands

And don’t hammer on the alternator bolts as they’ll mushroom out at the ends. Perhaps a small drop of oil along the studs to lubricate the dissimilar metals where they may have corroded from the dissimilar metals?

thanks.. was doing this, thinking the bolts were what was holding it in.

Fortunately I took the bolts out and didn't see any damage.

[john walker's workshop]

Originally Posted by KNS

I assume the removal process is the same for the 964/993 alternator and fan..?

The alternator, yes, the fan, no. Those fans are a bittch to get off the shaft. I finally made a special tool out of a large diameter steel pipe to be used in a press. I machined the inside of the pipe to allow the alternator body to enter, with some clearance and have the back edge of the fan sit on the edge of the pipe.