[alfa] Milano heater fan

[MCosgrove@xxxxxxxxxxxxxx]

I took the heater fan assembly out of my Verde this weekend for rehab.
Once out, I found the bushing at the squirrel cage end had fastened itself
to the shaft and spun, destroying itself.  So I took the whole thing apart
to try to repair it.  First question:  how much did Bosch save by fastening
the motor together by deforming metal tabs instead of proper nuts and
bolts?  $1?  Makes it very hard to work on.  Well, I got it all apart,
found some bronze bushings that happened to be the right ID, and made me a
replacement bushing.  When I went to put it back together, I had a senior
moment.  At the commutator end, there was a pressed on circlip holding some
washers on the shaft.  When I went to put it back on, I realized there was
a good 1/2" of shiny shaft sticking out of the motor housing.  Second
question:   What went between the clip and the motor housing? I can't for
the life of me remember, nor couold I find anything on the floor or
workbench that looked appropriate.  Anybody have an answer?  Well, I put a
length of my bushing material on the shaft to take care of any potential
thrust problems and put the motor back in.  Third question:  Can the
resistors look OK but still be bad?  I still only have high speed.  The
resistors had all the wires still in place.  Evidence of them getting hot,
but looked OK.  Could the switch be bad?  Any easy way to check? The wiring
diagram in the manual sucks, and the switch is a collosal pain to remove.
I have a spare, but would like to know I need it before changing it out.

Mike in Texas
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