[jkshadow2]

I have a 1975 911S with a '76 2.7L engine. I was having alternator issues, so I pulled the unit and had it rebuilt by a reputable shop. I had no issues removing the alternator (Valero brand) and the fan spun freely inside the housing.

I re-installed the alternator, fan, etc. with no issues. The fan spun freely inside the housing again. I re-installed the old fan belt (10x725), as it had no wear issues, and tightened it to 29.5 lbs. as directed by the manual. This caused the fan to move towards the alternator and pin it so that it does not spin freely. I think the interior of the fan hub is jammed against the sides of the alternator causing the impingement. So I pulled everything apart again and used a rubber mallet to move the fan to its rightful place. Re-installed a second time and before I could even get the fan nut to the proper torque, it pinned the fan again.

When I originally took the fan belt off, I found that there were only 5 washers instead of the required 6. When I re-installed, I used all 6 washers as directed by the manual.

Has anyone else had this problem? Is there a spacer that I need between the front of the alternator and the rear of the fan? There is no spacer shown in any manual I own.

Any help would be appreciated.