Woodruff key cut not deep enough on alternator that was made 2019

[Hannu911]

I’m not able to fit the fan on the WOSP alternator axel. It seems that the woodruff key stays too high.

I have two new WOSP alternators, one made 2019 and the other 2022. The woodruff key dimensions on both are identical.
The cut for the woodruff key on the 2022 made alternator’s axel is 0.9mm deeper than on the alternator made 2019.

The fan fits very nicely on the alternator made 2022 but not at all on the 2019 alternator.

What do you suggest I should do next?

[Hannu911]

Here is a picture of the cut depth measurement

[Hannu911]

Updated picture with Valeo measurement as well. 

 

 

Edited June 27, 2022 by Hannu911

[Jonny Retrofit]

HI Hannu,  I will raise this with WOSP.  In the meantime, the keys are very easy to file down.  Go gently until you get a good fit.

[Hannu911]

Thanks Jonny. I filed the key down by 0.9mm. Now it works. 

I would be interested in hearing what WOSP answers. My main concern would be the long term realiability.

Other question, what is the reason for the extra washer and lock washer between the nut and the tensioning cap (between parts 9 & 11 in the picture)? 

Is the tightening torques still 40nm as per Porsche spec?

[Hannu911]

It looks to me that these additional washers will not fit. So at least the washer needs to come out. But do I need the lock washer?

[Hannu911]

WIth just the lock washer added looks a lot better.