750 SF2 Bosch generator replacement/repair

[TeddyG]

I found yet another mangled part on my 750 SF2- the Bosch 0 101 209 0310 generator has badly stripped threads on the shaft and the keyway and slot are distorted from the nut that was left loose. The retaining nut won't thread back on. I'm not sure if this can be fixed, so can anyone offer info on a substitute? I've looked on Ebay and it appears to be a VW part for $300- $1000. Welding the pulley onto the shaft won't work due to aluminum to steel, but possibly a threaded bolt thru the pulley collar into the shaft might work. Advice welcomed, thanks

 

[TeddyG]

Never mind- I was able to tighten the nut over the mangled threads

 

[motoddrob]

I'd clean it up by running a die down the thread and using a new nut

 

[TeddyG]

Thanks- the threading at the top half of the shaft is completely smooth and worn away with no material left to use a die, but the bottom half has enough threads left to grab the nut. Hopefully it will last and I'll keep an eye on it

 

[RGS1000RGS]

Thanks- the threading at the top half of the shaft is completely smooth and worn away with no material left to use a die, but the bottom half has enough threads left to grab the nut. Hopefully it will last and I'll keep an eye on it

I'd have used some threadlock as insurance.

 

[TeddyG]

A die surprisingly brought back some of the mangled threads. I bought a new key way and nut and Locktite high-strength permanent, torqued it down, and then inserted a stainless cotter pin. So it shouldn't come loose again.