Back in March I had gotten the cooling fan and fan housing bead blasted, polished up and clear coated, then I mock assembled the fan to the alternator and the fan / alternator to the fan housing. At the time, I knew I would need to redo the assembly because I wasn't sure which way the spacer was supposed to be installed between the fan and the alternator. I didn't realize it at the time, but the woodruff key that locks the fan to the alternator shaft was loose rattling around inside the alternator - turns out when I clear coated the fan, the clear coat reduced the width of the woodruff key groove in the fan hub and the woodruff key no longer fit in the groove.
So today I disassembled the fan / alternator / fan housing assembly to correct the above issues.
Spacer between the alternator and the fan. The raised shoulder on the spacer goes down facing the alternator and contacting the inner race of the front alternator shaft bearing:
The spacer between the alternator and the fan properly installed:
The woodruff key on the alternator shaft:
Filing the the woodruff key groove in the fan hub:
Verifying the woodruff key fits properly into its groove in the fan hub:
Verifying the woodruff key is properly installed after the fan is pressed onto the alternator shaft:
Alternator / fan / fan housing parts from disassembly in marked bags:
Thankfully I took lots of photos during disassembly so I can figure out how to put the fan belt pulley back together.
Spacer shims for the fan belt pulley installed:
Outer half of the fan belt pulley installed:
