generator nut removal

mcruickshank · 04-18-2002, 05:15 PM

I can't seem to get the nut off. The nut that holds the pulley on the generator. I have the tool from the original tool kit. I threw a strap wrench on the pulley and can't get the nut to budge.

Anybody got a technique that works or am I missing a step?

Thanks,

Mark

Alan.UK · 04-19-2002, 12:12 AM

Have you tried applying a little heat to help it off? Not too much though. I normally let things like that soak for a while in a lubricant (WD40 or something similar) if that doesn't work apply a little heat and get a larger spanner so you can get some more leverage on it.

HTH

Alan.UK

mcruickshank · 04-19-2002, 05:32 AM

Is there another way to stop the generator from turning?

I have one wrench on the nut and a strap wrench on the outer pulley. Is there a better way to do this?

Thanks,
Mark

C. Clark · C. Clark's Garage

Hello,
I remove the nut from the pully end of the generator by placing a semi-large flat nose screw driver in the slot provided between the pully and the generator housing, wedge the driver against the screw head that protrudes from the generator housing, then rotate the wrench ccw to release it. My Porsche manuals all suggest this technique. Hope this is helpful,
Happy motoring,
Chas

Morrie · 04-19-2002, 02:47 PM

I have a little different method but seems to work every time.

I use a large Quick Grip bar clamp/spreader with the padded jaws and clamp it over the pulley. I then let the long trailing end of the clamp rotate down and rest on the engine support. Now I have both hands free to work the pulley nut. I tighten the clamp enough to hold in place and thats it. Mine was really stuck when I got the car and the notches in the rear pulley half were shot. This got it off. Be careful about the use of WD40 as this will require alot of careful clean up. It inevitibly ends up on the belt, and gets transferred to the flywheel pulley and then watch that belt slip.

Best,
Morrie

thomaslee · thomaslee's Garage

Check your local VW shop. There is a short very heavy very thick tool that goes over the nut. It is about 7 inches long and 1 inch thick. You then get out a hammer and whack the end of this tool - much like a impact wrench action. and presto - the nut is loose. I think it is made by EMPI and all VW shops (like bugformance)have them. If need - I can send you a picture of mine. Let me know...

josh912 · 04-21-2002, 08:59 PM

What C. Clark mentioned is what I always use. But it that doesn't work, one word: air. Bring it down to your local shop and take the impact wrench at it. If THAT won't take it off, wow, the PO was really strong.

mcruickshank · 04-22-2002, 06:29 AM

It came off.

In the process I:

broke: two drill bits

bent: two screw drivers

The recipe for success is:

lube and heat the nut.
Throw a large adjustable wrench (12") on the nut behind the fan.
Place the tool from the tool kit on the generator nut.
Call over the carpenter that is working on your house.
You hold the adjustable wrench tight as if your life depended on it.
Tell the carpenter to wack the crap out of the wrench on the generator nut with a hammer.

It is that easy.

Don't bother trying:
Drilling a hole throw the pulley halves and wedging a screw driver in the hole and into the generator.

or

drilling holes on both pulley halves in a line so you can pull them off in halves. Then cut out the spacers with dikes. The size wrench you need to grab edges that the pulley halves sit on is 20mm. Craftman's tools make wrenches up to 19mm, plus that space is very narrow and most tools don't fit in the gap.

After all that work and the car won't stay running. I am buying new plugs and wires today.

Oh yeah, the reason I was removing the generator nut. The inner pulley half cracked and and belt flew off on Rte 2 just west of I95 in Mass. The belt ripped apart two spark plug wires. I want to thank all the other Porsche owners that honked and waved as I waited roadside for a tow truck... did you really expect me to wave back? Nicely, a guy driving a boxster stopped and asked if he could help.

Well, it makes for a great story and I am a learning a ton about the car.

Thanks for all the help,

Mark

wastintime · 04-22-2002, 08:22 AM

Mark,
Glad to hear you got the nut to come off. Here's a suggestion for when you start replacing the pulleys and everything. I had a lot of trouble getting my generator nut off when i first bought the car, and it was because it had rusted to the shaft and the pulleys. I don't know if it's the cimate here or what, but even new pulleys, spacers, nuts, etc... that come from porsche seem to start rusting in about a week. VW supplies all of the exact same parts for about half the price and they can come chrome plated and they seem to stand up to weather a lot better than the porsche parts.

Andrew

C. Clark · C. Clark's Garage

Andrew,
Do you buy the VW stuff from your local dealer or a catalog supplier? The chrome pieces sound good and so does the price. How about giving a name for this place?
Happy motoring,
Chas.

craign · craign's Garage

Here is a place that I have used to get stuff for my 912, make sure you tell them it is for the 912. They are a great bunch of guys and if they don't have it they will bust a hump trying to find it for you.

They are located in Santa Cruz, CA.

http://www.volks-motorsports.com/

wastintime · 04-23-2002, 07:27 AM

Chas,

There are two places I like to order VW parts from. The first is CBPerformance http://www.cbperformance.com . I've heard mixed things about them on this board, but I swear by them. They're all really nice and they know what is and isn't compatible with the 912 engine and are a big help. Also, there's a website called The parts bin http://www.thepartsbin.com/vw_parts.html They probably aren't as good with 912s, but their products are incredibly cheap, and if you can get the exact same part for a lot less money from a VW place instead of a Porsche place....

Andrew

craign · craign's Garage

Harry Pellows book "The Maestro's Little Spec Book" has a great section in that back as to what is VW compatible with the 356 & 912.

http://www.hcpresearch.com/books.html

Guido · Guido's Garage

I just got the nut on the fan side off. That was impressive. I took the nut off the pulley side and set the shaft flats into a vise. I set up a 36mm socket with a 3 foot breaker bar and it came off. Almost twisted the vise of the bench though.
Anyway, I was wondering if anyone here knows if a fan for a VW would fit the 912s?

Guido

wastintime · 04-25-2002, 07:26 AM

The 912 fan is a VW fan, if you look at an original fan you can see the VW stamped onto to it. I believe the same fan used on super beetles is the one that fits the 912, but I'd check to make sure. It needs to be a fan for a doghouse fan shroud though, that's the big thing. Also depending on whether or not yours is pre or post '68 will make a difference since the fan thickness and # of blades was changed at that point. I know the above info is good for a '65-'67 though.