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Woodruff key disaster, advice needed

Discussion in '1st Gen. Tacomas (1995-2004)' started by davedave, Nov 27, 2024.

  1. Nov 27, 2024 at 2:17 PM
    #1
    davedave

    davedave [OP] New Member

    Joined:
    Nov 9, 2020
    Member:
    #346306
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    Male
    Here's my colossal screwjob on my 1997 2rzfe.

    Had a big oil leak, so I replaced my harmonic balancer and front main seal. After the job I ran it for a bit and all sounded good -- no issues. I then noticed another leak behind oil pump cover, so I went back in to fix that. When I removed my new harmonic balancer, I discovered that I'd messed it up -- I evidently didn't have it aligned on the woodruff key properly, so when I torqued it down, I put a hairline crack in the new harmonic balancer and pushed the woodruff key further down into the keyway. Not good.

    Taking a look at the key, it appears that it wasn't necessarily "grinded down" (like what happens when the HB spins on the crankshaft), but rather it was smushed/flipped down further into the keyway. I've now got a brand new harmonic balancer, and when I slide it on there's enough material on the existing key that it will "lock" into place like it should. However, I can't see what things look like on the back side of the key, which is mated to the timing gear. I'm not sure how much key is left there, or if the timing gear potentially cracked because of the pressure when i torqued the key into it.

    Here are my options:
    1. If I went in from the oil pan, do you think there's any way I could pop this key out to replace it? Because the back 1/2 of this woodruff key is aligned with the timing gear, I'm not sure if I'd be able to get it to budge -- but I haven't seen a great picture of what this looks like from underneath. If I have to slide the timing sprocket off the keyway to punch out the key, is there a way to do that without removing the timing cover? Any chance the chance can be loosened from valve cover and/or oil pan?

    2. It seems the only surefire way to replace the key is to pull the timing cover, which also requires pulling the head -- this is what pains the most. While the truck could probably use some refreshing on the top end (it's at 418k miles), I'm really apprehensive to pull the head. The truck has been rock solid for me it's whole life, and there's something about that factory seal that I think I'd never get back, but maybe that's just in my head.

    3. Just running it like it is. It already ran fine after I messed up the first install, and I had no reason to be concerned until I noticed it while I was back in there to replace the oil pump cover o-ring. As it is, I think there's a decent chance it would hold indefinitely and never cause an issue. However, I'm concerned about what damage I might've done to the timing gear when I torqued that key so hard into the keyway. If timing gear were to eventually crack and cause me to jump time, I'd likely ruin valves/pistons (and what else?), requiring a full rebuild. That's not the worst idea, but I'd hate it if it happened to ruin the block itself -- would love to keep original engine as long as possible.

    Other notes:
    - This truck has been in my family since it was new, and I plan to keep it forever. It's not my daily driver, and I rarely drive more than 20 miles from the house.
    - The engine runs pretty well; burns a little oil, but otherwise is excellent for having over 400k miles on it. Before I screwed this up so bad, I would've driven it across the country (if it weren't for the massive oil leak).
    - I'm not a mechanic, so I'm not sure if I'm worrying way too much or not worrying enough. Any and all advice are welcome.


    cracked_new.jpg remaining_key.jpg remaining_key2.jpg
     

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