Help with a Crank Pulley job gone wrong!

[humbucker87]

Hey guys,

So I was finishing up my timing belt job and it came time to tighten the crank bolt. I have a pulley holder but the little nubs that are supposed to fit into the crank holes always slip out under any serious torque. So I got some M8x1.25 bolts to thread into the crank pulley.

I got the crank bolt torqued to spec using my massive torque wrench. However, I looked down and my holder bolts were a little bent to say the least. One backed out just fine, but the other broke off in the pulley! Ugh!

It's not far enough back to hit anything behind the pulley, but I can't decide how to proceed? Do you guys think it will cause any issues? Could it throw the balance of the pulley off by any significant amount?

Anyone dealt with this issue before? Any help is greatly appreciated!

 

[jow]

1. Please share a picture of the matter.
2. IMO without seeing the Pic balance will be a concern.
3. IMO without seeing the Pic, why will a blunt pin punch not drive the broken screws out?
Good Lick!

 

[humbucker87]

Thanks now! Unfortunately the bolt is threaded in so as far as I can tell I can't simply punch it out.

A picture is a great idea. Here's the best I could get.

 

[jow]

1. Please share a picture of the matter.
2. IMO without seeing the Pic balance will be a concern.
3. IMO without seeing the Pic, why will a blunt pin punch not drive the broken pins vs screws out?
Good Luck!

Edit: If threaded, can you drill small holes to extract, thread out or cut slots to screw out. I missed the initial Pic.

 

[RPS13]

Drill + EZ out. If that doesn't work, I'd drill up to like 1/32" below the minor diameter of the bolt and then use a punch to work it out going in a counterclockwise method. Removing all the material will tend to release the load on the threads and allow it to rotate out.


If you have a welder, that's an easy fix, but I'm guessing you don't given you didn't immediately go there. Just tack another bolt to that, and use that to back it out. The heat also tends to release the threads.

 

[Mikep.]

Might be hard to get in there to drill or tap with the pulley mounted. Maybe there is enough threads coming out the back of the pulley to grab with a pair of vice grips. If you need to remove and reinstall the pulley, I would recommend a chain wrench. Wrapped around the pulley to keep it from spinning.

Good luck.

 

[jow]

1. Approx what dia are the broken bolts? Center punch to drill dead center w/o getting into the threads and the drill bit might remove it
(with threads oiled if you have room to Drill). As mentioned, “drill just below threads dia and work threads toward the center to rem them”.
Use a 90 degree drill attachment if needed and slow with oil. Reply is way to the right on long lines. LOL!

2. Bolts appear 180 Degree apart and about the same length, which might not affect balancing.

I hope they are out by now. If not, give them Hell!! Congrats On Your Job And Effort!!!

 

[humbucker87]

Thanks a bunch guys for all the immediate help. Space was limited and I tried some of the suggestions but ultimately borrowed a neighbors air impact and pulled the whole pulley back off. Used a dremel to cut a slit into the bolt and a screwdriver to back it out.

Now I just have to figure out how to torque it back. Might have to buy the chain wrench tool you mentioned. Thanks again guys.

 

[jow]

What is the dia of the bolts? Would a higher grade harden bolt work? What does the Dealer’s Tech’s use?

 

[RPS13]

This is where a manual makes this job REALLY easy. Just put her in 5th or 4th and wail away.

 

[emoore924]

I would have just cut a small piece of a similar bolt and screwed it into the other hole with a slot cut to unscrew it someday and a little loc-tite to keep it there until when someday came.

Balanced again. Job done.

 

[Sungod]

That tiny bit of weight that close to the center of rotation would have done nothing. You should have left well enough alone. If you have an impact that was strong enough to get it off, you should be able to use that to put it back. There really is no need for a torque wrench if you run it down with an impact.

 

[Geerlijd]

Removing the broken bolt will make it easier to remove the pulley for the next timing belt job. Since your engine will last forever, it was probably worth the effort.

 

[Dpassmore]

LH drill bit. Start small

 

[jow]

There are many ways to hold a pulley on a crank while torquing. I feel proper tempered bolts and steel is the key.
Some are seen at the link below. Good Luck to all of you and your methods.

What is the recommended Ft Lb of torque? How would you know you are getting that w/o a torque wrench?

Putting it in 4th or 5th relates to a standard shift. How does the dealer hold the Automatic's pulley?

Will the Channel/Lock/Chain Tool not leave any damage that will affect the belt?


https://www.google.com/search?q=wha...aR2E35_kM:&usg=__qSmIZ8dTl0cJ6FFH_afp0KBXMUc=

 

[RPS13]

Putting it in 4th or 5th relates to a standard shift. How does the dealer hold the Automatic's pulley?

Duh... that's why I said it's easy in a manual, as in manual transmission vehicle.

 

[unclfstr]

I know it might be a little late now, but I wound up using the serpentine belt to hold the pulley. If you cut the belt to make it a straight length, wrap it around the pulley in the opposite direction to what you need to do (clockwise for koosen). Make sure you overlap the pulley at least a half a turn and then take the free leg and wrap it around the frame; passenger side seemed easier to me. Holding the free end of the belt with one hand should give you enough grip to keep the pulley from spinning.

Sorry for the lack of pictures, by the time realized that my strap wrench wasn't going to work I was so frustrated I just wanted to get it done...

 

[iBison]

I would have just cut a small piece of a similar bolt and screwed it into the other hole with a slot cut to unscrew it someday and a little loc-tite to keep it there until when someday came.



Balanced again. Job done.

That was going to be my shade tree suggestion. [emoji3]

 

[humbucker87]

Just wanted to say thanks again to everyone. I hope the suggestions here can help anyone else that this might happen to in the future.

With the confidence of borrowing the air tools I tightened the pulley back on in the exact same manner and was just extra careful removing the severely bent bolts from the pulley. They both came out but I was likely seconds away from being in the same position. I like all of these suggestions though.

Also, fyi, once I had the pulley out I dremel'd a slit into the bolt and backed it out with a screwdriver. That was a fun weekend! Not