Removal of 617 fan clutch (checked FSM, searched here and DIY articles) with pics
 

I've been working all day on replacing my timing chain tensioner and tensioner rail. (The tensioner went fairly smoothly. Had it off in probably 45 minutes, but the rail...)

The problem is that I can't get the stupid radiator fan clutch and/or pulley off.

I tried to bypass removal of the clutch and just remove the pulley, hoping the whole assembly will come off together. I used PB Blaster and per the instructions, I "tapped" the heads. Actually, I hit them from the side with a long steel bar and a hammer. I only managed to ruin two open-end 10mm wrenches. (Boxed-end and sockets won't fit with the clutch on.)

Notice in the pic of the clutch(bimetal strip removed), there are no bolts or clips - visible anyway.

Any ideas???

Many of us have ground down a box-end wrench until it fits. I don't think there is a better option.

Thanks TF!

I ground down the wall thinner and that got it!

How do you remove 617 fan clutch?
 

Can you tell me how the clutch is mounted on the shaft. Is it threaded? As you point out, there is no bolt behind the cover plate on the clutch. Is removing the 10mm bolts on the pulley the only and/or best way? I can't find any diagrams or other tech commentary on this job.

Thanks.

Jim

The 10mm bolts are the only way.

How did the chain rail replacement go? I did not know you could replace it witout major engine disassembly.

Its probably to late, but I'll throw my two cents in anyway.

I removed and installed two fan clutches today from an 84 and an 85 300TD (swapped them around).

On one I had to remove the radiator anyway and eventually the waterpump, the other I just did the fan assembly.

I used the open end of a regular Craftsman 10 mm combination wrench with a 2.5 ft cheater pipe on it to loosen the bolts. No PB blaster was needed, no hammering, no problems at all.

Take all four 10mm bolts (going through the water pump pulley) off the foot of the fan clutch, and the fan/fan clutch should come right off (maybe a small tap on the foot of the clutch if its rusted to the pulley. Pop the clips off the top of the fan shroud and lift out the fan and the shroud at the same time.

Loosen the three 17 mm bolts on the back of the alternator bracket, loosen the 13mm alternator belt adjustment bolt, slip the belts off the water pump pulley and the pulley should just come right off with a little tug.

I did it, but...
 

it wasn't too easy.

here's that thread...
http://www.peachparts.com/shopforum/showthread.php?t=192292