EMBPilot

88 miles to home. Here we go. This sucks.

EMBPilot

Andreas, thanks
I agree w you. My hunch is the belts are / were too tight.
I have plenty of shims but now this pulley is stuck on the shaft. Might be able to get it off w my puller.

It's possible that they were a little too tight since we put them exactly 12 months ago and that the excess ambient heat a few weeks ago put it over the edge. Which is possibly what caused the original alternator shaft to strip under the shaft nut? Too tight again this time has managed to get this pulley stuck this time around.

Quadcammer

I'm not sure I agree with the belt theory. Yes, the belts were tight, but given that no changes were made to the shim setup, and there was no noise for however many miles, it seems unlikely that this time they were that much tighter. There was about 1/8th" worth of deflection on the alt pulley. Given a little bit of belt stretch, you end up at about 1/4" of deflection. If anything, a brand new hub should resist excessive belt tension better than the old one.

I think this alternator is easily saveable.

sigh...

mjsporsche

Kevin and Oliver,

You guys will need some time off for good behavior after this is finally sorted out.

Good luck with sorting out the issues. The flatbed was a sad sight.

Mark

Dudley

Have you measured the belt tension? Napa has the Krickit gauge for @ $10.

Techno Duck

Time for an LS1 swap..? .

Your making me second guess a 993 now.. (just kidding).

EMBPilot

I have a cricket here at home. I will use it once I get as far as putting another belt on.

lol Jon, I might need ur merchant marine engineering and p-car expertise down here when u get home!

ToSi

Does the backside alt pulley half match the outer? wondering if you have a mix of updated vs original pulleys / spacers.

See: https://rennlist.com/forums/993-foru...or-pulley.html

Looks like there might not be enough thread to fully seat the pulley halves together & slight wobble in outer pulley is damaging the shaft. Did you feel the nut 'bottom' or did it just build torque smoothly against the side of the belt?

PS: if you decide to punt, the RS fan (964-106-015-40) includes the RS pulley hub (993 106 051 80)...

EMBPilot

the nut felt like it slowly laid up against the pulley.

if i need another new alternator, and this one has to go back I will do the RS set up, since i dont drive the car at night/ in traffic anyways

first i need to figure out how to get these pulleys off the alternator shaft and see what were working with.

i think there is plenty of thread on the shaft. the guy said its a re-man alternator, didnt say from who, im assuming bosch, but the threads that it came with look a little gnarly on the very end of the shaft... the nut however is working fine and its putting out good volts unlike the old one.

one thing is clear, when the alternator shaft is 'unloaded' the noise stops...

Quadcammer

we updated the alt pulley when we did belts in february.

I think however, that the belt used was the 760mm pre-update belt. Could that have resulted in the pulley sliding onto the shaft too far and the nut butting up against the shaft?

ToSi

Both halves of the pulley? New belt is 757mm, so should be on the loose side if anything.

Quadcammer

unless the shop gave me back the wrong pulley halves, both pulleys halves were updated when we did it back in feb.

EMBPilot

the pressure is off since the car is back home now... im in no rush but i want it to be right.

the car has always had the updated pulleys on it. we labeled the pulley halves when we did the belts a year ago but all the writing is gone off the pulleys? the pulley halves look identical.

it was a real challenge getting the alternator pulley off. it could spin freely on the shaft but it would not come off. i used emery cloth, a lot, to smooth the shaft and was able to get it to slide off. was not pleasant by any means. and it barely came off, as it stands now theres no way id be able to get it back on the shaft in its current state.

with the alternator first pulley half came a shaving of the thicker part of the alternator shaft. (photographed)

not looking that the nut threads at the end of the shaft, thats how i got the re-man, and the nut threads on there fine, (but looks bad!)

looking at how bad the shaft is here, it is all roughed up, im not sure if this is something i can take emery cloth or a dremmel to and smooth it all back out so the pulleys slide back on there smoothly?

i feel like i can take this to my trusted LOCAL shop who i have a relationship with, he'll prob want to replace it, then i can reinstall with more shims.

or i can attempt to smooth the shaft myself. and try to fit it all back together using more shims on the alternator.

the fan had 2 shims and the alternator had only one.

Quadcammer

holy ****. good work dude.

slap it back together if you ask me.

Quadcammer

did you find anything upon disassembly? Any bolts loose or such?