Nightmare! Porsche fan belt tool wont fit!!!

[Porschepilot79]

Hello all, I the 10mm Porsche tool part# 999.571.052.02 and it will not fit in the hole. I cant get the generator pulley off to put on a new belt since my old one snapped. I don't get it did Porsche make to sizes to fit in there? I don't even see a 9mm tool made anywhere or a record of they even used that size for this application??? Any help would be great. thanks!

[nzp964]

I have the same problem with a replacement unit from Bosche. In my case the hole appears to be an imperial size rather than metric and a similar tool from an classic American car enthusiasts toolbox did the trick.

Some time in the future I'll have two new shafts made (the old alternator works fine but its shaft is bent) but in the mean time I'd be interested if you track down an easily available tool for this.

[Groesbeck Hurricane]

I believe this is a slot for a hex tool? If so, work with your hex keys to see if one will fit. If you have trouble holding the hex key still while removing the nut you can place a metal pipe over the key to provide more of a fulcrum and help hold the key in place. If this does not work or you do not have a key set, you use a measuring device to ascertain the opening size and go to a tool shop (sears, matco, snap-on, harbor freight) and buy a socket based hex key.

If this does not make sense or does not help in your application, please post a photo of your fan so we can be sure of how the nut is attached to the pulley.

[Porschepilot79]

Here is a picture. It looks like a allen type hole in the in middle of it? If I use the triple square side which imperial size would that be? I hope the small allen doesnt break?


[IMG][/IMG]

[Groesbeck Hurricane]

I apologize but the photo would not load from work and I had not had time to sign on at night from home...

What you are showing would, I believe, require a star drive. It appears many teeth have been stripped out. You want to attach on to the large area, not the small one in back. Autozone will loan out some tools, I would check and see if they loan out the star drives. I am also sure there are people in LA with this tool. If you were closer I have several sizes to choose from.

An alternative: Do you have a filter wrench, one of the rubber ones, that will wrap around the pulley without damaging it? You could then use your wrench to loosen the nut. I have a pipe wrench with a chain that I have used for this in the past. You must be VERY VERY VERY careful not to damage the pulley!

[lucittm]

The part number you cited, 999.571.052.02 is correct for this application and this tool is part of the Porsche-supplied tool kit. Someone used the wrong tool (10mm Allen?) in the past and rounded off the female teeth of the alternator shaft. A new alternator may be your only recourse. I don't know why these pulley nuts are so hard to remove, the torque spec says 10 +/- .7 ft-lb (14+/- 1 Nm). A dab of Loc-tite would be useful here too.

Mark

[Hamptonsam]

I ended up taking the whole alternator out and held it by the bolt on the other side (got lucky that it worked), but I was changing to the RS hub that only has one belt for the alternator. I now only need an Allen wrench to change out the one belt. I feel that this is a lot easier on the side of the road.

[dewflex]

Someone had rounded mine off before I bought the car. I had an allen cap screw cut off and welded in the hole so I could use a common allen wrench. Works great, and much cheaper than a new alt.

[Porschepilot79]

Originally Posted by Groesbeck Hurricane

I believe this is a slot for a hex tool? If so, work with your hex keys to see if one will fit. If you have trouble holding the hex key still while removing the nut you can place a metal pipe over the key to provide more of a fulcrum and help hold the key in place. If this does not work or you do not have a key set, you use a measuring device to ascertain the opening size and go to a tool shop (sears, matco, snap-on, harbor freight) and buy a socket based hex key.

If this does not make sense or does not help in your application, please post a photo of your fan so we can be sure of how the nut is attached to the pulley.

Thanks I used an allen key and the size that fit was 3.5mm allen in the center. I will go and get a socket in that size to use to hold it better and try that.

[Porschepilot79]

Originally Posted by Groesbeck Hurricane

I apologize but the photo would not load from work and I had not had time to sign on at night from home...

What you are showing would, I believe, require a star drive. It appears many teeth have been stripped out. You want to attach on to the large area, not the small one in back. Autozone will loan out some tools, I would check and see if they loan out the star drives. I am also sure there are people in LA with this tool. If you were closer I have several sizes to choose from.

An alternative: Do you have a filter wrench, one of the rubber ones, that will wrap around the pulley without damaging it? You could then use your wrench to loosen the nut. I have a pipe wrench with a chain that I have used for this in the past. You must be VERY VERY VERY careful not to damage the pulley!

They call it a triple square which is 12 point. I will try idea with the belt wrench this if the allen socket fails me. Thanks

[Porschepilot79]

Originally Posted by lucittm

The part number you cited, 999.571.052.02 is correct for this application and this tool is part of the Porsche-supplied tool kit. Someone used the wrong tool (10mm Allen?) in the past and rounded off the female teeth of the alternator shaft. A new alternator may be your only recourse. I don't know why these pulley nuts are so hard to remove, the torque spec says 10 +/- .7 ft-lb (14+/- 1 Nm). A dab of Loc-tite would be useful here too.

Mark

The teeth were rounded but not to the point that it should have still worked I felt. The problem the porsche tool is to big?? An 8mm triple square is to small so it would need to be 9mm or 9.5mm to fit?? I cant find anywhere that makes this tool in 9mm or 9.5mm to try and see if it fits??

[Groesbeck Hurricane]

I believe Snap-on, Matco, and Sears should all carry those in 9mm

[sled9146]

You might want to use the old VW method:

YouTube - The Volkswagen Generator Belt Change

[mongrelcat]

Belt and Pulley Replacement - Rennlist Discussion Forums

[Porschepilot79]

Originally Posted by sled9146

You might want to use the old VW method:

YouTube - The Volkswagen Generator Belt Change

This vid is to much!

[Porschepilot79]

Originally Posted by mongrelcat

Belt and Pulley Replacement - Rennlist Discussion Forums

Nice link. They say the size is 10mm? Did Porsche make a 9mm size you think or maybe my Porsche tool didn't fit because it was not made correctly? I will try the snap on they used on that link and see if fits.

[Traveller]

Originally Posted by Porschepilot79

They say the size is 10mm? Did Porsche make a 9mm size you think or maybe my Porsche tool didn't fit because it was not made correctly? I will try the snap on they used on that link and see if fits.

It might not fit because of the rust build-up within the splines. You might need to jiggle the bit in slowly till it fully seats.

Take a digital caliper and measure the internal distance across the valleys. It should be 10 mm give or take.

I just bought a Snap-On bit and it is a tight fit which is what you want if you want to prevent damage to the internal spline of the alternator shaft.


Alternator Belt/Pulley Tool

[AtlBchGator]

All, I know this thread is 2 years old, but I came across it searching for the same 999.571.052.02 polygon wrench or a work-around. The same tool is called for automatic trans removal for a 2000 Boxster.

I found the 10mm 12 point triple square at Northern Tool (Performance Tool 12-Pt. Bits (Triple Square) — 4-Pc. Metric Set, Model# W1395 | Star Keys, Bits + Drivers | Northern Tool + Equipment) in a set with the 6mm, 8mm, and 12mm. Set of four for $3.99. It worked for my application, but I'm not sure how much room you need with the fan belt problem (tool is a bit big, 1/2" hex drive, and it's about 3" long) Anyway, if that link doesn't work or someone finds this years from now the northern tool Item # is 9094124, and it says Model # W1395

Hope this helps anyone having the same problem.

Cheers.