crankshaft pulleys half millimeter too small.

So i have a 2004 2.7l motor with the two outer crankshaft pulleys cracked from two of the bolt holes to the inner edge of the pulley. Im in the process of welding them up right now. But i have a 1999 tacoma with the 2.7 as well. I pulled the pulleys off the 99 so i could have my 04 running while I take care of the cracked pulleys. However the pulleys on the 99 are about half a millimeter too small on the inner edge. So in order to fit them on the harmonic balancer i would take a dremel and barely grind up the inner edge.

My question is how perfectly do the pulleys need to line up on the harmonic balancer since they bolt into it anyways?

 

best to use the right part, it is a balancer, and its needs to fit perfect...

 

you sure that 99 wasn't a 2.4 and not a 2.7 engine? they "look" identical in every way but the numbers.

if it was a 4wd it was a 2.7 but if not you need to check

I would NOT weld them, I wont even get into weld penetration and stress and hardening it after or being able to mill the inside and outside diameters and all that but even if you are extremely talented you still wont be sure its perfectly round again and it will unbalance the engine and things will become damaged from being out of balance, its not worth saving $10 at the salvage yard so throw the broken one away and replace it

 

Have you tried some heat? Rose bud or just the little torch that screws onto the cans?

It may make the pulley swell enough to go on. It'll need to be hot enough to sizzle and bead spit but not red hot, as then you'll affect the temper.

 

The balancer is fine. my problem is the outer two crankshaft pulleys dont fit onto the balancer perfectly.

their both the 3rz. And I have a buddy who is a welder for a living. So i would have him make sure its all good to go. Im not touching the balancer, its the outer pulleys that slide onto the balancer and then bolt into it.

I havent tried that yet but might give it a go.

 

So I just found out that my problem is being caused by the harmonic balancer i got from napa.

The the pulleys are all the same. they even have the same part number branded on them. however they are slightly too small to fit over the napa harmonic balancer.

In the picture i have the pulley sitting on my old (Stock) balancer. The inner edge of the pulley slides perfectly over the inner lip of the balancer and is all good. However on the new harmonic balancer i would have to really force it to sit flush and at that point it would be impossible to line up the bolts

 

damn, you can usually trust napa for good parts that fit, that sucks.

hopefully you can get a full refund and order oem replacement from rockauto.com so you know you will have the right part that fits.

oh ok, I see what you are talking about now, but still, it should be very easy to pick up some used pulleys for nearly nothing at the salvage yard then you don't have to try to retemper the soft metal after it has been welded.