Supercharger Pulley Upgrade Disaster [HELP!]

Hey Guys, So I really messed up this one. Not sure how many are familiar with this upgrade, but this thread gives the detailed steps. I got the old pulley removed fine, following those instructions. I then heated the pulley at 300 for an hour and verified with a temp gun. Went to put the pulley on and quickly realized I didn't have the right tools (using channel locks basically) but pressed on anyway...big mistake. I didn't get the pulley on all the way before it cooled too much and ended up stripping out half the supercharger threads. Admitting defeat I went ahead and removed the pulley. This resulted in large gouges being taken out of the shaft. So now I have a ruined pulley, a damaged shaft and stripped threads. Hoping I could get some opinions here on how to continue.

1) Ruined Pulley - Buying a new one, but guess I'm going with red this time

2) Damaged Shaft - Would this affect the next attempt at an install? I was just going to smooth it with fine sandpaper and scotchbrite it. Thoughts?

3) Stripped Threads - Hard to tell, but it looks like about half the threads have been stripped out. Why URD uses a hardened bolt stronger than the supercharger threads is beyond me, but guessing they don't want anyone to blame their kit. Should I try repairing the threads? Re-tap? Would anyone happen to know the bolt size and thread pitch? It will be difficult to line it up perfect, so feel this is risky, but not sure of other options. Why didn't they make the allen key screw longer for this task? Also, they included two different ones that look slightly different (pic below) with no instruction as to which one to use. I think my #1 move is to repair the threads and find a longer allen key screw to take advantage of the back threads as well as the repaired ones. Thoughts?

 

I stripped the threads on mine after install. I think the URD tool is junk...
Unfortunately you may have to replace the shaft. Not sure the terminology on what all needs to be replaced or how to do it. Maybe contact magnuson or try https://www.jonbondperformance.com/

 

Oh wow

 

You may be able to get away with some time serts. I've used them to repair some valve cover bolts, and other things, depending if you can find the right thread, and if there wI'll be enough meat on the shaft to retap and thread in. https://www.amazon.com/TIME-SERT-Metric-Thread-Repair-1812/dp/B001JK44LG

 

Agreed. What did you do to fix your stripped threads?

 

This sounds promising. There is plenty of meat left there to tap I believe, but was wondering if I could get away with just re-cutting and using the good threads in the back of the shaft. Maybe too risky. Is this the right size? It says M8 and I believe it is an 8mm bolt on the URD tool...

 

Not sure if it's the correct thread pitch. You could always take the bolt to a hardware store, and match it up to a correct size nut to get the right thread.

 

I had to retap the threads. But ended up using the wrong tap. I was able to install new pulley using the urd tool but stripped the threads doing so. I don't recall the size I was trying to find it in a different thread but can't locate. If you tap it make sure to some how catch the shavings in the inside of the super charger. I believe it goes through the whole shaft.

 

i use timeserts and regular helicoils all the time! i think you will be fine assuming its a press fit, i think youll be fine.

 

The hole size and thread pitch is M8x1.25.

 

Good to know, thanks for looking that up! Looks like trying a timesert for that size is the best path forward, so will start there.

 

Oh, damn it... sounds like something I would do... thats why I took mine to the shop to have it done... wishing you all the luck in the world!!

 

If it comes down to it you could buy my truck. Supercharger already installed with 2.85 stealth pulley.

 

There is nothing wrong with the URD tool if used properly. You screwed something up royally when doing it, like trying to press it on REALLY crooked? The shaft is a lot harder than the cast pulley, so you either had it really crooked or picked up some metal somewhere when you went to put the pulley on? Maybe you screwed the threads up when removing the pulley at the start and things went downhill from there? Just try a longer allen screw, buy a cheap toaster oven from walmart, put it right next to the truck, bake at 425 for a half hour or so. It's easier to have the tool all lined up on the supercharger and use pliers to put the hot pulley on the tool to install, that way you can make sure the tool is properly lined up with the shaft.

 

This sounds like the easiest solution so far!

 

I did have a toaster oven right next to the truck. Had it set to 300 for an hour and temp gun showed 300 on the pulley. As for the gouges, I'm 99% sure that I took too long with the pulley install and the pulley/shaft cold-welded itself from the friction of the pulley sliding on. Then, when pulling the pulley off, it took the chunks of the shaft with it. Those chunks are actually still stuck to the pulley. High amounts of friction between different metal types can result in some interesting bonds. Basically, if they would make a 2.85 pulley out of steel like the original, this would not have happened - but that would add whole dollars to the cost and no one wants that!

 

Time-sert kit and new pulley have been ordered. URD recommends I take off the front shaft from the supercharger and use a hydraulic press instead. This of course comes with the complications of taking apart the supercharger and changing the oil, etc....that will be my final attempt after trying the re-thread. Will update with results.

 

Did you have the threaded insert fully installed into the tool? I had that problem when installing and resulted in some stripped threads. Good lube and being careful to install a good portion of threads into the snout and not the tool are important. You can read about my experience here:
https://www.tacomaworld.com/threads/urd-2-85-stealth-supercharger-pulley-install.416267/

 

Appreciate the response. I actually based my install off of your thread, but looking back I should have taken better note of your issue with the stripped threads. Basically, I had the set screw threaded 50/50 between the insert tool and snout. Now that I know the threads of the supercharger are weaker, maybe that should have been more 25/75. But I also made the mistake of trying again after stripping the 50/50 threads not paying attention to exactly what happened when all of a sudden it got easier to spin and probably went 40/60, stripping out even more threads as the extra 10% wasn't holding on. There are probably still 50% good threads left in the supercharger, so I might be able to go with a longer set screw as even the stripped ones still allow the tool to thread in properly - just not sure I want to risk those giving out as well and starting over yet again...

 

Does anyone see an issue with how this guy installed the pulley? Allowing the pulley to move, but with a ratchet on the end, so the tool spins as well?
https://www.youtube.com/watch?v=O09IeFA9uWg