Generator Shaft not locked to pulley - can't undo.

Hi all. New to this group and VW's. Just picked up an 71 1302s 1600 auto a couple of weeks ago and it didn't have a generator pulley, so I stuck one on to get me the 2 hours drive home. I noticed at the time the slot in the shaft for that circle locking thing was a bit sloppy. Drove home checking it every so often. Seemed to go sweet. Next day I noticed the pulley was rubbing on the generator housing so I tried to take the pulley nut off to put in some more spacers, but the shaft is turning and isn't locking onto the pulley so I can't lock it with a screw driver to undo the nut. Any ideas on how I can get it off? The guy who had it before me must have put the pulley on backwards cause it has rubbed the bolts on the generator and then the centre bit of the pulley broke and he lost half the bits. He didn't know the shaft drives the fan and just thought the battery would go flat so I'm lucky it ain't cooked I guess. I think he had the generator done and then stuck it in himself, with the pulley backwards. I hope he hasn't stuffed the bushes and that. I don't know if the circle locker thing has popped out somehow or if the centre of the pulley is broken again as it is hidden under the bell shaped bit. Thanks for any help.

Reply to
scream
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I have a bad feeling about this one :-(

Grind/saw the nut off.

Or, Behind the fan there is a 36mm nut on the other end of the shaft. Get a 36mm socket back there to hold the shaft.

But...I bet the shaft is knackered from the roundy thing wallowing out the cutout. (It's called a Woodruff key.)

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Speedy Jim
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Reply to
Speedy Jim

Thanks for that. Think I'll give the back nut a go if I can find a socket that big! I guess if i have to resort to sawing I might as well pull the generator out and try vice gripping the thread first since it will be stuffed anyway right? Can you replace the shaft or will I need a new generator? I could try making another fatter woodruff key. maybe weld it in if I really had to. Appreciate you help.

Reply to
scream

If you're up to pulling the gennie, maybe get am alternator kit to replace.

Or....weld the key in! I Like it.

Speedy Jim

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Reply to
Speedy Jim

It's time for the high-speed grinder.

Reply to
j

I just used a bit of Loctite.

Reply to
Michael Cecil

Thanks for all your help guys. I got it off thank goodness. I trotted down and got a 36mm socket (those things are expensive) Then I tried to undo but the fan nut came loose instead. I did it up tight again, sprayed heaps of CRC on the generator nut and after much heaving it came loose. The woodruff key fell out and is a bit munted. The pulley sleeve thing had pushed right back to the generator bearing which exposed half the key and caused rubbing. I'll post some pics on my website in the next couple of days if anyone could take a look, as I'm not sure if I'm missing something there. I'll post here when I've done it. Really pleased I got that thing off without wrecking anything. Thanks for your advice. I got some locktite too, but it just looks like superglue. Is that the same stuff you guys use? I'm from New Zealand. Don't know if it's different in the States. Andrew

Reply to
scream

Ah. Thanks for the informative update.

Loctite is great stuff. Different from SuperGlue. Loctite comes in various flavors for different applications:

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Jim

Reply to
Speedy Jim

Andrew,

IF memory serves, 36 mm is also used for such things as the castle nuts on the rear hubs, the gland nut that holds the flywheel on... and maybe somewhere else that I've forgotten about.

As to the Woodruff Key, I'd find a machine shop and try there.

I just dug into my catalog pile and found that J-Bugs has the Woodruff Key for seventy-five Cents, US... catalog is a couple of years old, so maybe a dollar US plus shipping? Their catalog number is N-127-051, btw.

I'm not sure, but I think that these are the folks that I once delt with in person in Hawthorn Calif.

AR

I'll be danged if I can find a spec for that key and if I went out to the garage to find one I'd spend half the night looking for it and the Rest looking for my Micrometer!

Reply to
AR Ogden

Thanks for all that research AR. I think a standard woodruff won't fit so well now though. I do have the old one but it is a bit banged up. I have put some pics on the back of my website here showing the problem

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you guys have time, would you take a look and tell me what you thinki should do here? Glad to hear my 36mm socket will come in useful again. Andrew

Reply to
scream

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