help: impossible timing belt pulley cog removal

[NoSlo]

Hey, tips to get this thing off?? The main pulley was incredibly tough, and the timing pulley on the crank is near stuck. I've already broken a puller bolt on the crows foot type puller and had to drill and clear the threads with a tap. I finally got the pulley to move about 1/2 inch, but now it is stuck again and the puller feels like any harder and I'll break it. Torching the cog and wd40 no help. At least no crank cancer!

 

[SVOFANATIC]

The only thing I could suggest is a grade 8 bolt and get the crows foot as close to the pulley if not touching it as possible.

 

[kevinspann]

Is the woodruff key jammed in it? Push the timing gear back on it and make sure it's not wedged somehow.

 

[Off Road SHO]

What he said. Woodruff key might be distorted just enough to jam it up even tighter when trying to remove it. Don't use WD-40 except to dissolve the oil varnish buildup. Use PB Blaster or ATF and acetone mixed 50-50. As a last resort you can heat it up with a small oxy-acetylene torch or plain acetylene torch to expand it a little. You're going to replace the seal anyway, right?

After you get it off, make sure to clean off all the varnish on the crank snout AND the inside of the timing gear. Always re-assemble with a very light coat of oil and a new woodruff key unless yours is perfect.

Tom

 

[NoSlo]

Got it off, got longer bolts and bigger puller, also a new 14x1.50 thread bolt so I didn't have to tear up the top of the crank bolt to pull. I recommend all get new hardened M6 bolts to do this pull if you don't know if it will come off easy!

 

[NoSlo]

I think the difficulty might have been working in 28 degree temperatures. The main seal was equally difficult to remove and replace even after torching the engine some and deep freezing the new seal. There was still rubber sticking to the inside of the seal surface on the block (the seal and engine had become one) that I removed by wrapping sandpaper around 2" PVC. However, the cleaned timing cog and main pulley slid right on after setting them on a fireplace for a few minutes until they were too hot to handle without gloves.

 

[kevinspann]

A little bit of lubricant always helps too.