Crankshaft Bottom Pulley - Ruined Crankshaft Key

[mongo]

Hi all,

 

The xantia is just back from the garage, where they said its a replacement engine job due to the lower crank pulley being broken. The alternator belt was not rotating, but only occasionally would.

 

They said they couldnt fit a new one as it had ruined the crankshaft. Im guessing it has ruined the slot that the pulley goes into. Recently the car has just had alot spent on it (timing belt/tensioners, spheres, ignition barrel and full lockset and brand new clutch) the car drives beautifully.

 

The engine has only covered 117k and its a strong as an ox, its a 1996 1.9TD with bosch pump.

 

Im quite tempted to try some JB weld on the lower pulley around the key area, or does anyone else have any alternatives?

[techbod]

ahh so that's why you need to remove the pulley, I doubt the crankshaft has broken and more like what you said ( the woodruff key has disintegrated and screwed the pulley up ) so get a woodruff key and pulley from a breakers yard, jb weld lol no chance that will hold it however I have seen them mig welded in place as long as you don't put too much heat into it because it will melt the timing belt so pulse welding is best ( a little at a time and let it cool to prevent overheating)

 

a quick edit#

 

to do this you have to lock the flywheel at TDC then torque up the center bolt locking the pulley on then weld the bolt to the pulley that's if you cant replace the woodruff key and pulley of course

[mongo]

the car is actually running the bolt has been tightened right up, but the garage said they have no idea how long for as it was not worth replacing the bottom pulley due to the damage.

 

Thats why i was saying possibly JB weld... I am really loathed to take the car to the scrappy since it runs so nice!! Thanks for the quick response though.

 

If it does go to the scrappy i may well have a full lockset (which was brand new a couple of months ago) and other parts off the car first!

[techbod]

stranger as it unfolds so the timing belt pulley woodruff key part is ok and only the woodruff key alternator side is shot? if yes then jb weld might work, you could also place a large washer before the crank bolt then drill and tap it so you could fit a locking bolt and bend one side of the washer up the side of the bolt to prevent it spinning loose, just a thought and would eliminate the need to weld

[mongo]

stranger as it unfolds so the timing belt pulley woodruff key part is ok and only the woodruff key alternator side is shot? if yes then jb weld might work, you could also place a large washer before the crank bolt then drill and tap it so you could fit a locking bolt and bend one side of the washer up the side of the bolt to prevent it spinning loose, just a thought and would eliminate the need to weld

 

 

Got the car to my mates garage. In the end we replaced the lower pulley with a spare second hand one (from an engine we had lying around and a spare key). The groove for the key in the crank was double the size, however it was ok under the timing pulley (just a tiny amount was left in the timing pulley enough to keep the engine going!).

 

I wish i had taken pictures of the crank pulley before i binned it. It had half the metal left on the inside of the pulley , you know the solid steel section that is a full circle, well only half was left.... We cleaned the crank/timing pulley area then put in the new key and then applied JB weld to the extra space in the key location on the crank. Slapped on the lower pulley and tightened it right up and have applied a line of paint between the bolt and the lower pulley and the washer to make sure it hasnt "slipped".

 

Back motoring again :P 300 miles and its still all perfect.