OK, i had a misstep, but I understand now how this works. I knew i had to tear it down and start over, so I loosened the battery quick disconnect, buy apparently not completely, as during the disassembly i got a big spark (and scare!) just after I removed the ground and warning light wires. I must have tilted the alternator to a ground while it was still getting juice.
Once the alternator was on the bench, I was lucky enough to find the Woodruff key laying below the lower (crank) pulley. That "shiny" concentric piece went in as John W. and Lee said it would, and the whole unit went back in the car without too much of a fight, other than that $%**## air guide, POS.
With the washer against the alternator bearing, Woodruff key in place, it took 2 shims in and 4 out to get proper belt tension. However, despite all of this, with fan and belt turning, it isn't charging...as noted by the warning light staying on and the VOM showing the battery DISCHARGING, NOT CHARGING. True even when revved up. I think the spark was a warning that i either damaged the VR or the alternator itself. Confident it is wired correctly. But I've also posted the wiring as viewed on the back of the alternator. The red paint blob is the positive terminal. BTW: I checked the fuses and they are all fine.
thanx steve
