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Old 09-27-2011, 12:27 AM   #1
thomas18a
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Default Losing Cam Pulley

Hi everyone,
I got a 2004 wrx wagon. It has 87k now. Recently, I have a horrible oil leakage from the cam seal. Thus, I decided to replace the belt, pump, cam seal, crankshaft seal...together
The problem is I cant figure out a way to lose the cam off.
Is there any special tool which i need?
thanks
Thomas
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Old 09-27-2011, 04:55 AM   #2
amalgrover
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the cam sprockets are one of those things that people break often even if they are using the right tools. they suck to say the least. there are special tools. http://www.amsperformance.com/cart/a...cket-tool.html here is a link to the PROPER tools, but with a big breaker bar (and maybe a cheater bar on the end of that) and some muscle, usually you can get them. try not to break the cam gears if at all possible. i usually will dremel the bolt heads off if they won't come loose because the bolts are MUCH cheaper than the sprocket is.
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Old 09-27-2011, 01:09 PM   #3
thomas18a
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Quote:
Originally Posted by amalgrover View Post
the cam sprockets are one of those things that people break often even if they are using the right tools. they suck to say the least. there are special tools. http://www.amsperformance.com/cart/a...cket-tool.html here is a link to the PROPER tools, but with a big breaker bar (and maybe a cheater bar on the end of that) and some muscle, usually you can get them. try not to break the cam gears if at all possible. i usually will dremel the bolt heads off if they won't come loose because the bolts are MUCH cheaper than the sprocket is.
Thanks for the information. Is there any lower budget tool? 174 for a tool is a little bit out of my budget..thanks
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Old 09-27-2011, 01:22 PM   #4
Cool Hwip
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It's a $700 job if you bring it to the dealership so it's hard to complain about $174.
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Old 09-27-2011, 06:26 PM   #5
amalgrover
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if you are looking for the cheap route, just cut the bolt head off if you can't get them loose...the bolts are less than $10ea
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Old 09-27-2011, 07:08 PM   #6
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You use the old timing belt, two Vise-Grips, and someone that's strong enough to hold the belt when it's clamped up and wrapped around the alternator or A/C pulley to hold the cam-gear pulleys in place while you loosen the bolts.

Did it both times, off and on for a friend's car. No broken bolts. No broken cam gears. Approximately 140,000 miles on the engine.
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Old 09-28-2011, 09:45 AM   #7
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Quote:
Originally Posted by Big-E View Post
You use the old timing belt, two Vise-Grips, and someone that's strong enough to hold the belt when it's clamped up and wrapped around the alternator or A/C pulley to hold the cam-gear pulleys in place while you loosen the bolts.

Did it both times, off and on for a friend's car. No broken bolts. No broken cam gears. Approximately 140,000 miles on the engine.
This is how i will do it in the future, and How I recommend it be done. It's how I have always done it on my older cars. However, when I did the suby, I had a friend at a dealer loan me the dealer tool. I chipped the cam gear, even though I was using the proper tool. I was pissed.

If you do it like this, DO NOT RE-USE THE TIMING BELT!!!
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Old 09-28-2011, 10:05 AM   #8
amalgrover
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Quote:
Originally Posted by Big-E View Post
You use the old timing belt, two Vise-Grips, and someone that's strong enough to hold the belt when it's clamped up and wrapped around the alternator or A/C pulley to hold the cam-gear pulleys in place while you loosen the bolts.

Did it both times, off and on for a friend's car. No broken bolts. No broken cam gears. Approximately 140,000 miles on the engine.

a few times on higher mileage BIG horsepower cars this has not worked for me, the proper tools didn't work for me, and the breaker bar and cheater bar wouldn't work for me. in those cases the only solution is to cut the bolts off. obviously, this is a route i try to avoid on customer's cars, but sometimes it is the only option when 500+CHP has been pulling those bolts tighter and tighter for 75,000+ miles.
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Old 09-29-2011, 12:15 AM   #9
thomas18a
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Quote:
Originally Posted by amalgrover View Post
if you are looking for the cheap route, just cut the bolt head off if you can't get them loose...the bolts are less than $10ea

I finally got 3 of the bolts off with an old timing belt. how can i cut the bolt head off, the bolt head is in the pulley..is it?
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Old 09-29-2011, 07:38 AM   #10
amalgrover
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you can do it 1 of 3 ways pretty much...

1. use a dremel and a cutting wheel. start by making a line right across the bolt head (a gash so to speak), then make another line that makes a cross with that one (make a cross), then make another line that intersects those two, and then keep doing this until you have cut down to the pulley itself (don't cut the pulley though) and the bolt head will fall right off. (this way took me about 10-15mins)

2. use a drill bit slightly larger than the shaft of the bolt and start drilling into the bolt head. eventually the bolt head will fall off the shaft. (this way took me MUCH longer than the others...like 30mins)

3. this way isn't actually cutting the bolt head off, but more just giving yourself leverage. basically cut a gash in the bolt head just like in the first way that i told you, but make it so you have a flat spot to rest a punch on top of. then you would hold the pulley with the old timing belt as you did before, and using a hammer and a punch try and back the bolt out. i have found that this in combination with the first way works the fastest. sometimes you can get the bolt head cut about halfway off and it will start to turn loose using this last method.


...let me know if any of this didn't make sense and i will try to explain it better.
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