bruce7

This thread is about repairing a stripped thread in the fan housing for the
AC bracket. I don't call it a DIY because I hired it out, having it done at
TRE Motorsports in Van Nuys. The car was in for a fan hub bearing
replacement and alternator rebuild so it was convenient to have them do it.

The photo album can be found here:

https://plus.google.com/photos/11229...14878461748545

The solution basically was to install a Time-Sert thread insert. I also added
another washer to help keep the screw from going down the plastic hole in
the bracket.

For some interesting videos about the time-sert product, click on the product
demonstration link at: http://www.timesert.com

mpruden

Good call on the time-sert. I've goofed up and stripped this out on my car as well. (glad I'm not the only one!)

bruce7

Just got the car back today. The rebuilt alternator self-destructed and caused
some collateral damage. I had the alternator rebuilt when the fan hub went
out by TRE Motorsports in Van Nuys. They sublet the rebuild of the alternator
out to CAE in Van Nuys. Went about a month and a half then I heard a
screech one morning. Checked the belts and the alt belt was loose, down to
maybe 10 kg tension. I tried to remove the alt nut but it seemed to be
cross-threaded. So I tightened it back up and went over to TRE. They couldn't
get the nut off either. They said they would tighten it back up and order a new
nut as it would be destroyed when they got it off. Then they sent me on my
way back home, about 9 miles. I had reservations about not leaving it there
but it was their idea. It progressively got worse and the fan was beginning to
scrape the housing. I parked it until they were ready to take it in. I wasn't there
for the autopsy but they said the alternator welded itself to the fan hub. They
put in another rebuilt alternator, refinished the housing, put on new belts and
alternator pulley and fan hub. I think they addressed the fan blade tips too.
The refinish has a silver look compared to the original grey look but I'm liking it.
They also covered 2 days of car rental. I believe they media-blasted it then did
the final refinish. Don't know what type of finish it is.

Here are a couple of pictures of the new look:

pp000830

I like those aftermarket belts! Some say OE belts only. I have used the Dayco belts for years without problems. Looks like your car, like mine, has the Porsche TSB pulley update.

The quality of alternator rebuilds seem to be all over the map. This is probably because many rebuilders only replace failed parts or reject rotor cores that function below some in-house performance standard.

Ideally if one could take your own alternator to the rebuilder directly and specify all the parts you would like changed out a more reliable rebuild could be had.

Through my tier one automotive manufacturer experience I have learned that many OE branded aftermarket sold new and rebuilds are not built to the same performance standards as factory installed units.

For certain parts the market is awash with counterfeit OE branded products. This had become a huge headache for OE Brand manufacturers that sell service and remanufactured parts as they see product failures frustrate their customers and sully their reputations.

Andy

JasonAndreas

Those are genuine OE.

bruce7

Hi Andy, You are probably right about the aftermarket rebuild quality. One thing
I've noticed is that on my original alternator I could use the Snap-on 12 point
socket BLPXZNM3810 but it won't fit the new shaft. Will have to use the
Porsche polygon tool instead.

RichPugh

Bruce, I am sick and tired of all your "Helpful" and "Selfless" posts. Why cant you just ask questions about burnouts and imaginary special tools to do basic services. Ughh... :wink:

bruce7

Hey thanks Rich! BTW, I'm enjoying your rebuild thread. Later, bruce

pp000830

I thought OE belts were Porsche branded on the actual belt as purchased from the dealer?

bruce7

You mean like this?

pp000830

Yes, the belts I get from Pelican do not say Porsche on them although I am sure they are made the same way. I have also used Contitech belts to good effect.

http://www.pelicanparts.com/cgi-bin/...&I1.x=0&I1.y=0

Andy

kjr914

Bruce,
Is the final surface smooth (like pc/paint/clear) or just a little textured? Having just media blasted 2 of these (one partially by my own hand) it looks like it was just blasted and not clear-coated, but hard to tell from Internet photo sometimes.

Asking since I'm debating what to do with mine...paint/pc clear or just al natural.... Still liking the look?

And I did the same with my housing, adding a timesert due to the bolt being stripped out. I'm not going as fully as you have to replace with OE bolt/washer however....

bruce7

Hi, thanks for the questions. I just went out and touched the surface and to
me it feels smooth like clear coat, however, it doesn't shine like a clear coat.
There is no glint from the sun that I can see. There doesn't seem to be a
coarseness like you might expect from a casting.

I've got a call into TRE to find out some more info about the finish which I
will post up when they get back to me.

Yes, I'm still liking the look. I didn't check out what the options were to do
the refinish. Not sure if it's possible to anodize it to match the factory look
or not and how much that would cost.

I like the time-sert solution. That's the way it should have come from the
factory. Also, the aluminum manifold should probably have time-serts as well.

bruce7

OK, got some more info on the fan refinishing. The housing was media blasted
by J and P Deburring in Chatsworth. Their website is here:
http://jandpdeburring.com/index.html

The housing was not clear coated, that is the natural magnesium appearance.
It will turn grey slowly over time according to TRE.

-bruce

kjr914

Thanks! That's what I thought, as mine's currently media blasted and looks identical to yours. I've got to decide if I clear coat (paint or pc) it or just leave it. Clear coat would be slightly easier to clean off gunk, but prone to chipping, etc...hmmm, decisions decisions...