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Old 01-01-2013, 06:52 PM   #1
Scooby Newbie
Member#: 129738
Join Date: Oct 2006
Location: Blacksburg, VA
2003 WRX
Aspen White

Default 1996 Legacy Crankshaft and Pulley

This is on a 1996 Legacy but I thought since it's a generic issue maybe this would be the best place. I just wanted to show the pics and see if anyone has suggestions. I know the pulley has to be replaced and it looks like the timing belt needs to be done anyway as it seems to have cracking. I'm not sure what's up with the crankshaft and timing pulley though, or what it's supposed to look like. I know there's a key but I don't see a key or a slot for it on the crank, just a big pitted place. I didn't want to order any parts until I know what can be done here.

See Pictures

Last edited by vlcmstnsct; 01-01-2013 at 06:54 PM. Reason: images
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Old 01-01-2013, 07:27 PM   #2
NASIOC Supporter
Member#: 165749
Join Date: Dec 2007
Chapter/Region: South East
Location: Central Floriderp

Looks like there may be some damage or almost like someone modified the end of the crank for some reason. That belt is very close the end of it's life, as you suspect. With the condition of that belt and the way that crank timing pulley look I would not run that engine.
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Old 01-01-2013, 08:50 PM   #3
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Member#: 294461
Join Date: Sep 2011
Chapter/Region: NWIC
Location: Grass Pants, OR
2006 San Remo Wagon
Under construction


Pull it all apart and take better pics.

Near as I can guess, someone under tightened the crank bolt which allowed the terribly designed crank pulley to spin and shear the key/warp the keyway. Your best bet will be to see if the right side (as you're looking at the front of the engine) of the keyway is okay, find a new woodruff key, and shoot a weld into the gap on the left side of the keyway to hold the crank gear in place. The pulley will stay in place without the key if you torque the bolt properly, and doesn't need to align. The crank gear obviously has to align in order for the engine to run; thus you weld it in place to eliminate any play.
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Old 01-01-2013, 11:25 PM   #4
Elbert Bass
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Member#: 283429
Join Date: May 2011
Chapter/Region: South East
Location: Down yonder.

The woodruff key is still in there but the front part of it is broken off. The pictures tell me the pulley got loose, wobbled, and broke the key. The wobbling pulley and broken key have eaten a groove in the crankshaft and timing gear.

To properly repair that you will need to remove the crankshaft and have a machine shop weld up and regrind the nose of the crank and the keyway, then replace the timing gear and pulley.

Yes, that time belt is done for - quite a long time ago.
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Old 01-02-2013, 10:24 AM   #5
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Member#: 30669
Join Date: Dec 2002
Chapter/Region: Tri-State
Location: USA, North NJ, 07456
1998 Legacy 2.5GT
Silver Sleeper BK, 5MT


Yes, pull the covers, make sure the crank & timing gears are lined up, then pull the belt & crank gear.
It's hard to tell, but you/we need to see the condition of the end of the crank, preferably with a straight edge against the side to see if the crank is OK.
The crank gear "may" need to be replaced as well as the crank pulley. The 2 surfaces (at least on the newer ones) should be flat where they mate up.
I would also look to replace the crank seal while it's apart since it looks to be leaking oil.
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