Broken crank pulley

Zef · Jan 20, 2023

This is a problem entirely of my own making - I was careless in tool usage. I feel somewhat stupid about it, but heck it's a fantastic learning opportunity.

Removed the crank pulley this morning and it came "off" a little easier than expected

Any ideas how to get the rest out? I'm not sure there's enough lip left for any puller to grab hold of.

TJ Jim · Jan 20, 2023

Damn. Vise grips? Cut a slot as deep as you can back towards the seal, then insert a chisel into the slot and attempt to split or crack it open a bit and make it easier to slide off?

Zef · Jan 20, 2023

TJ Jim said:
Damn. Vise grips? Cut a slot as deep as you can back towards the seal, then insert a chisel into the slot and attempt to split or crack it open a bit and make it easier to slide off?

I was also thinking about getting a Vice grip (or bearing separator?) on there too have something to pry on - but I'm not sure I'll be able to pry it off.

Other option is splitting it or using a punch to try to break it up.

jeepguy03 · Jan 20, 2023

Maybe remove the timing cover and then you will be able to get a bearing puller behind what is left of the pulley? If the seal on the cover hits those rough edges leftover on the pulley you might have to grind that down.

Zef · Jan 20, 2023

jeepguy03 said:
Maybe remove the timing cover and then you will be able to get a bearing puller behind what is left of the pulley? If the seal on the cover hits those rough edges leftover on the pulley you might have to grind that down.

This sounds like a great idea! Thanks!

Zef · Jan 23, 2023

jeepguy03 said:
Maybe remove the timing cover and then you will be able to get a bearing puller behind what is left of the pulley? If the seal on the cover hits those rough edges leftover on the pulley you might have to grind that down.

This worked! The metal was so soft I just filed it down and was able to remove the timing chain cover. Then used a bearing separator/puller to get it off!

Replacing timing chain and sprockets since I'm in there

Thank you for the advice!

jeepguy03 · Jan 24, 2023

Zef said:
This worked! The metal was so soft I just filed it down and was able to remove the timing chain cover. Then used a bearing separator/puller to get it off!

Replacing timing chain and sprockets since I'm in there

Thank you for the advice!

Awesome! Good to hear.

Zef · Jan 24, 2023

Before:

After filling down sharp edges and removing cover:

Bearing splitter/puller installed:

Done

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Broken crank pulley

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