harmonic balancer fell off while driving, that was just the beginning...

I'm on my third toyota truck in 40 years, a 2008 with a 2.7L 2TR-FE 4 cylinder. I was riding up the road and the crank pulley fell off after fifteen months of great trouble free service. Didn't know that could happen until recently. Anyway, got a new balancer cause the old one got buggered, had it machined, and it fits good. The problem is that the woodruff key got sheared during this and is locked too tightly in place and cannot be changed. Is there any possibility of attaching the new pulley to the crankshaft by any other method. ?? I'm getting no vibration and the engine still runs smoothly, so no timing issues. Obviously, without an alternator and water pump, I don't run it too long. I just cannot afford the time and expense of a new crankshaft right now. Otherwise, I've got scrap metal. Thanks.

 

Post a pic if possible of the crank

 

Use a cold chisel and hammer too remove whats left of the key from the crankshaft.

 

There is no way to get anymore out. It is fixed, as in bonded to the notch.

 

For some reason my url entry will not post the photos. ??

 

Use the camera button to upload a pic

 

well as last ditch effort, there is one option that i can think of, if the key way is broke off flush and cant be removed. (and you have tried everything to get it out) then you could install the balancer and try drilling a hole that cuts into the balancer and the crank, kinda like making your own key way, then hammer in a piece of round stock then reinstall the bolt. this is not the best option but might be only option.

 

What does the machine shop say? Find an old machinist and see if they have any ideas.

It’s really too bad all the WW II Navy machinists are gone. Those guys could fix anything.

 

I find it strange that the harmonic balance sheared the key to begin with. I would want to know why it all came apart. That should not happen the bolt has
shouldn't work out from vibration or rotation.

It is hard to believe that the key remains cannot be removed from the crankshaft groove.

Have you consulted with a real machinist?
Was the bolt not installed?
What kind of condition is the groove for the key?
How did you get the replacement on with the remains stuck in the groove?

I hope you get a chance to post an image, I for one would love to see this un-removable key.

 

I've used a dremel tool with their small cut-off wheels to slice mashed keys in half, and then use a punch and hammer to drive them out once the pressure is relieved. It takes a steady hand but it works well.

New owner as of Monday.

 

Someone in the past took the balancer off and didn't torque it back on properly

 

I had the rubber on mine come apart and threw the belt which then destroyed the oil seal.

 

All good comments. THANKS to all. I still can't get this old computer to post this picture. I want y'all to see this. EME, That was my very thought for the fix. Drill a hole, small pin. MY CONCERN WAS MAINLY ABOUT BALANCE EVEN THOUGH I DON'T THINK AN OUNCE AT THAT POINT COULD CAUSE VIBRATION ? IT DID NOT WHEN THE OLD PULLEY WAS HANGING ON SIDEWAYS. Jimmyh, I totally agree, but that key has become one with the crankshaft notch. TOTALLY FUSED The remains of the key were sheared all the way back to where they did not obstruct full depth installation of the new harmonic balancer. Obviously, it wasn't torqued but took the fifteen months that I have had it (138K, and very well maintained when I bought it) to shake loose. IF ANYONE KNOWS THAT TORQUE SPEC, I'M GETTING 190 FT/LBS, PLEASE CONFIRM. And I tried a dremel, not even close to heavy duty enough. one more thing, DOES ANYONE CONCUR WITH EME (MEMBER) ON A SMALL DRILL AND PIN ? THAT WAS MY ONLY SOLUTION. THANKS AGAIN TO EVERYONE. would appreciate further comments. CLAY

 

Crank pinning is a fairly common procedure for a shop to do with the V8/blower guys, but to do it on the vehicle usually takes a kit just for that engine. Otherwise it's an on-the-bench procedure. Good luck.

 

If you have to pin it, you could get a fairly straight shot if you pull the radiator out. Maybe condenser too and go through the front

 

Keep in mind.

The key serves several purposes. It locates the balancer, it also will transmit torque.

Frankly, I suggest to find a machine shop that specializes in Classic Car Restoration. These guys need to recreate parts that are no longer available. I'm reasonably sure, they have dealt with sheared keys before. If not, they may be able to offer a solution to remove the remains of the key.

 

It is not a press fit and it's half moon on the bottom so if you drive it downward at one end it should lift the far end.

 

Woodruff keys can be a bugger to remove when sheared.

You could try heating the shaft with a torch, use a 3 lb Blacksmith hammer and a punch. Drive the punch down towards the centerline of the shaft near the end of the key. The woodruff key should rotate a bit lifting the opposite end of the key.

Good luck.

 

Fused to me implies something like welding. I can't imagine that being the case here.

I can see the key having been torqued to jam a corner of the key into the side of the keyway though. As well as some transference of key metal onto the crank along with some polishing the key down before the HB fell off.

You've probably already tried this, but I'll throw it out there anyways... With the key at the 12:00 position, strike the key down into the groove with a blunt end. If the key got torque locked, a couple of good whacks should free it as well as breaking up the polished edges.

Good luck!