Generator freewheel - Torx key rotated completely around on generator shaft

Hello everyone,

Engine: Audi A4 B6, 1.9 TDI, engine code: AVF.

I changed the timing belt and water pump yesterday. Since I had the front of the car in service mode once, I decided to replace the alternator's freewheel clutch at the same time.
Unfortunately, I stripped the Torx socket on the generator shaft. The freewheel was just too tight... Do I need a new generator now, or is there still a chance to fix the problem?
Thank you!
Best regards, Hufe.

Try opening it with the impact driver. "Just do it like that; it's not the best thing for the tools, but you don't really have any other choice right now."
When getting dressed, do it with care and attention.

Quote:

Try opening it with the impact driver.

That should work... if not, use the angle grinder and cut it open..

Hi,

Before using the flex machine, I would disassemble the generator and place the rotor into a...
Secure the vise.

Regards,
dieter

The impact wrench works great, as long as someone hasn't already really hammered it and damaged it.

It was the impact driver that rounded off the Torx screw.
I had the Lima clamped in a vise.
But apparently, the wave is made of aluminum or something similar. In any case, it wasn't hardened steel. I've left the freewheel on for now and reinstalled the alternator. Currently, besides the mentioned Flex solution, I don't see any other options.
But if I flex the freehub too much, I won't be able to tighten the new freehub properly because of the recessed Torx screw... It's a vicious cycle. Damn!

Hufe is referring to the "Torx" (or is it an internal Torx XZN ???? ) to hold in the shaft.
Leave it out as long as the weather permits. Then it's probably time for a bra replacement.
Next time, please use the appropriate tool.
hg
Herbert.

"@Hufe im Freilauf" refers to a type of connection, and there's a specific nut used for it. With that nut and an impact wrench, it should be possible to loosen it.

Quote:

In free-running mode, there is a toothed connection, and there is a special nut for it, and with that nut and an impact wrench, it should be possible to loosen it.

No - the free-running clutch has a specific type of spline, and the shaft has an XZN spline. With the right sockets for both, you can achieve the same result - without using an impact wrench.
Herbert.

Thank you, Herbert!
I meant the XZN spline on the shaft. I had the right tool with the appropriate clamping mechanism.
But the wave interference destroyed it. It seems the only option is to replace the entire generator.

It's not quite that bad, but including the wave... You won't be able to save Rotor.
hg
Herbert.

Hufe wrote:

It was the impact wrench that rounded off the Torx screw.

Not surprised. Using the impact wrench, you should apply force to the splines of the clutch, not to the shaft.

What he means by that:

Due to the inertia of the anchor, you do not need a counter-holding tool (M10 internal Torx) when using an impact wrench.

Simply insert the XZN 33 (the large multi-tooth socket) into the impact wrench and unscrew it with short, leftward movements!!

It should work, and even if the multi-tooth wave is severely damaged...

Quote:

Only insert the XZN 33 (the large multi-tooth socket) into the impact wrench, and unscrew it with short bursts to the LEFT!!

Exactly! ... It has to work.

Possibly, he also used the wrong bit for the shaft.
I've once broken a bit "manually," but the teeth remained intact.

The problem is that, in a short amount of time, sufficient power must be available to overcome the breakaway torque. And that can only be achieved with the correct key sizes.

Therefore, always check beforehand to ensure that the tool being used is tight and fits perfectly.

The question is only how "firmly" the pulley is attached when it spins freely with the impact wrench without any resistance.
I have both projects in front of me right now.
hg
Herbert.

Herbert wrote:

In free-running mode, there is a toothed connection, and there is a special nut for it, and with that nut and an impact wrench, it should be possible to loosen it. Quote: No - the free-running clutch has a specific type of spline, and the shaft has an XZN spline. With the right sockets for both, you can achieve the same result - without using an impact wrench. Herbert

I didn't mention the XZN spline in the runner. Just use the special socket and open it with the impact wrench; in 90% of cases, it will come off without the runner resisting. And no, you don't need a new generator or runner, even if it doesn't come off with the impact wrench. With a little skill and a small angle grinder, you can remove it quickly without damaging the runner's shaft. And if the millimeter disc's thread has a small notch, the runner is not yet broken.

And @Herbert, the freewheel needs to be tightened to 70 Nm. And if someone who isn't completely clueless hasn't already tightened the freewheel, I only need to press the impact wrench once and the freewheel will come off. Sure, it will be a bit tighter than the 70 Nm because it automatically tightens when the engine is running.