nizzle

Ok so here is the VERY short version of a VERY long story. My pulley fell off (wasn't torqued to the +90 & wasn't my fault... don't ask) and sheared off my woodruff key. Didnt want to have to remove the timing cover, chain, gear, etc. to fix it. SO, did some research and found a good solution (IMO) for a fix. Thanks to GT-ER, Shardul, Chawkins and everyone else who chimed in with good info, ideas, and support. Sorry for the HUGE lack of details but it would be nothing short of writing a novel to explain the whole situation. Anywho, here are a couple pics.

drimmeled out the end of the crank a little



Then JB welded in a super strong piece of steel (not sure the exact kind/grade) bolted the pulley up and torqued it down CORRECTLY and...... as good as new or better IMO

FT-Performance

Good luck with your new fix!! Way to many Pulley Failures are happening lately.

nizzle

^ Thanks & Very true! 148 ft lbs +90 or FAILl!!

chawkins2001

Did the snout get scarred up at all? How long has the new pulley been on there, done any WOT blasts, and could you put a vid up of it at idle?

209sl55

Where (and what size) did you get the new keyway? I'm in the same boat. Thanks

nizzle

Snout not scarred. It's been on since last Friday. Haven't done any COMPLETELY wide open blasts but I've got into it pretty good. No vids yet but I will try. I am not proficient at putting them on youtube so you might have to watch them via photobucket but we'll see

nizzle

Got it from a local machine shop. Not sure of size but had to do some filing.

GT-ER

Looks good. Do some extended wot runs before you claim victory but I think you got it.

nizzle

Not only did the pulley falling off shear my woodruff, but it also made my sack shrink (lol JK). I'm still a little too nervous yet to do a wot run. Lemme grow some ***** back and I'll do a couple wot runs and let you know if it holds.

GT-ER

lmao...if it's going to fall of it's going to do it at the worst time so beat on it close to home and cross your fingers.

Denroll

People talk smack about JB Weld, but it's some amazing stuff.

BenzCLS06

^^^This. U might as well try some WOT close to home just in case.

stevebez

Been wondering for those who had this all go bad on them ... Perhaps the end of the crank snout can be machined to a spline / rib profile and a blank ring fitted over it , to shim to oem size/ spec or have a pulley machined to match the spline... Mbe there is a reason this is not done already but just a thot ... Of course means some pretty high tolerance engineering and crank out the motor ...

jt2ma71

Back in school my instructor told my always to use a bit of loc-tite on crank bolts. Come to think about it i dont think i ever have though. Ive never had a single car come back for a loose pulley either.

I think if i ever do take the crank pulley off this car, i think i may put a bit of blue loctite on there just to be on the safe side..

nizzle

If it is not torqued right, loc tite will not help at all. Had 148 ft lbs & loc tite on it when it fell off. The +90 on our crank blots after the 148 ft lbs is everything

jt2ma71

Yeah thats a given. Its a torque-to-yield bolt, without that 90 degrees its going to come loose.

I think your fix will hold up just fine, assuming that is the crank bolt is correctly torqued! Good luck!

benz_addict

Good work. Good to see it fixed! But wouldn't this cause the crank to be out of balance?

Forrest Gump 9

No, the amount is so minute and so close to the center it won't matter.

To the OP, good luck. If I was you, I JB weld the bolt in there for good.

AgSilver

There is actually an FAA approved repair to the Continental TIO 520 series engine cases to stop oil leaks using J.B. Weld. Yup . . . good stuff!

jcjmw

Sorry to hear that. I am starting to think that this problem is more common then anybody knows. Luckily, GT-ER came up and shared his solution which seems the easiest and best solution. If you need help, just ask and I am sure anyone here will offer whatever they can to help you.

nizzle

thanks

If for some reason my fix doen't work, I may consider something along those lines but I didn't want anything to be permanent like that unless necessary. Who knows? I might wanna change pulleys again...

i guess technically it could be but the car feels fine. I dont notice anything negative

BBBSS

Stories like these makes it scary to buy one of these cars used.

slownrusty

I wonder how long the JB Weld will hold up (long term)?

e55amgrocket

We have JB weld on a engine block on a excavator at work that has held up since 2003 (I remember putting it on the week after i graduated high school lol) Still hasn't leaked to this day and its had another 2000-2500 hours put on it. That stuff is great!!!

nizzle

I put a mark on the bolt and the pulley so I can check to see if the bolt appears to be backing out/loosening, and it has not budged at all. I have done some good power runs but I am waiting for the weather to clear up in the next day or 2 for a couple WOT runs.