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Old 06-11-2011, 01:08 AM   #1
02redwagone
Scooby Specialist
 
Member#: 87067
Join Date: May 2005
Chapter/Region: AKIC
Location: Oregon Coast/AK
Vehicle:
02 Old but tasty
SRP

Default My pulley was worbling. I went anyway.

Somewhat useful information when the worst may have happened to your pulley and or judgement.

My pulley was wobbling... Loose bolt, key misaligned, both. I'll never know root cause.

-I somewhat hesitantly drove 600 miles to the bay area from the Oregon coast anyway. No issues yet. Car sits for a week.
-I drove back up I5 all the way to Medford. Whats that?!? An odd scraping noise that is somewhat rev amplified. Oh as if I don't know damn well what that could be. I had thrown a non returning misfire code just north of Weed. (in hindsight I'm surprised that's all that happened with the amount of metal in the case and on the sensors)
-I fiddle with the pulley in the schucks parking lot. Bolt wont move so nothing is about to fall off at thousands of RPMs. But something is definitely getting eaten.
-20 miles later limping into valley of the rogue park its apparently finished eating as the AC belt is only on by one rib. The pulley is now only turning by friction against the snout and the round twisted remains of the key. Wobbling is a gross understatement.

-6 hour wait for backup with tools. Big screwdriver for the flywheel (since its a 4eat). A 4 foot jack handle. Half inch HD ratchet with new 22mm socket. Lets tear this mother off and slap the Kartboy unit that arrived hours after I initially left on this bitch!
WTF is up with this? It will tighten a few inches and loosen a few inches but will not thread out. It just ****ing wont! I finally twisted off the bolt with no dramatic sounds aside from low IQ rage grunting. The pulley fell to the ground in a puff of metal, dust and rust.


$400 dollars in logistics later its home.


-I tried and broke various assorted bits in a 2 week marathon of drilling bolt remnants. Left handed tit coated steel... useless. Lefty solid carbide from Italy...drilled ribbons then snapped in half 30 seconds later. Cobalt with lowish revs and high pressure worked the best. Carbide certainly worked but was extremely sensitive to shocks which is a bitch when drilling blind intersecting holes via a mirror by hand.

-Eventually it was the 6 inch shaft carbide cone burr that DESTROYED the remnants of the bolt. That being said the bolt won. I couldn't get the last shell bits out and by then the thread was half erased anyway.

-So in the end I got the tap set out and found 14 to be cutting rather shallow so on to 9/16-18. Tapped perfect threads all the way back to the break and the matching inch and a half long grade 8 bolt fit perfectly. I found a USS standard 9/16 hole x inch and a half OD washer and on they went. Cleaned sensors (looked like they grew beards), belt, case, reset timing, new sprocket, key, tensioner and pulley. JB weld to shore up the slight trauma to the key-way (dusted so it wont fuse to pulley). Blue locker on the bolt this time. Fires up on a half crank and runs smooth enough to stack champagne glasses on.


CN: Pulley wobbles, drove 750 highway miles anyway. Pulley gets lose after having the key port and polish the inside all over timing goodies. Rust, dust and locked threads ensue. This leads to a solution and overall better then before performance.

Some pics later.
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Last edited by 02redwagone; 06-11-2011 at 03:10 AM.
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Old 06-13-2011, 10:16 AM   #2
Bacon117
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Member#: 118500
Join Date: Jun 2006
Chapter/Region: MWSOC
Location: Michigan
Vehicle:
02 Silver Wagon
"Stage 2"

Default

I'd go away if my pulley was worbling as well...


The crank is hardened, and IIRC, the bolt is grade 8. Not easy to drill as you found out. Hopefully, it all holds together, and doesn't grenade on you. Good job.
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